Creo Mold Analysis Extension

so today's the webinar agenda our objective is to review and demonstrate Creole mold analysis extension and the agenda we'll do a brief introduction and then we'll talk about Creole mold analysis extension overview you know what is CMA why use it how to access it and then we'll follow that up with a application demonstration we will review the results and generate a report and then we'll have a Q&A session and during this time all attendees will be muted and we will take time at the end of the presentation for any questions if you have any questions during the presentation please feel free to type them into the meeting question box on your screen so a little introduction about myself my name is John Hughes I'm a technical specialist with boundary systems my background is an application development and product design primarily in plastics I started working with PTC creo formerly Pro II in 1995 and have been working with injection molding design and simulation since 2002 now about boundary systems we are a technology leader of partners include of course PTC etroesch and other technology companies we're number we're in the top 16 fastest growing private companies in Greater Cleveland we are part of the pds vision group of global companies our capabilities are in PLM data management CAD design and consulting simulation and product development boundary systems has received many awards the Inc 5000 Weatherhead 100 we are accredited with PTC as a platinum partner chill certified implementer we are PTC prefers service provider and authorized certified training partner in creo windchill mathcad and Arbortech also about boundary system solutions besides the products provided by a PTC we also support tacked on each Raj key shots molex 3d X formation ITI ZW cad sig maxim and some eric's so what is creo mold extension the creo hold analysis extension CMA it's an easy and effective tool to simulate injection molding you can use it to analyze a single component to help evaluate and determine the number of gates one or more and the location or locations required to produce acceptable product in addition it can be used to analyze a single cavity Multi cavity or a family cold run or mold layout is designed or to determine if the design is acceptable for injection molding or if modifications and other considerations are required with the melter livery system the part itself or both and this is all to provide an optimal guidance and direction before costly tools have been designed and manufactured and then you find out whether or not there's some errors and mistakes that could have been avoided early on so why and when to use Creole mold analysis and we talked about some of the reasons to use it early on but some of the uses that I have used it for again is to evaluate gating requirements quantity and locations in addition you can evaluate multiple materials oftentimes your application is not specific to one material and there be up may be other candidates that are viable candidates as well as if you design something and it's not functioning well and you need to make the change changing the material for other properties you can go and evaluate that material change within the analysis we can also evaluate the mold layout designs with the melter livery systems as well as we can do some minor modifications within the Treo part file itself and then evaluate the effect of those changes in the creo mold analysis extension now without saying anything further let's go into the product demonstration so what we have here is we were challenged to evaluate this one plus one cavity family tool as currently designed so we have our Creole model opened up access the mold extent or mold analysis extension it's as simple as going through the applications mold analysis and it launches us into this interface in the ribbon that is very similar to your creo parametric that do you use so as we have this here we have a few options here that are shown it's as simple as just a few selections so we have materials gates and then the analysis but it's in the sequence of left to right so if we know what the material is specified we can actually go in the materials here and as we can see from the material library that's built into the it's broken down by material family types and it covers if I'm not mistaken over 6000 to 6500 individual materials so it's shown by family type and then under each family type we have manufacturers so it's easy to identify and find the material that you need or perhaps if it's a very unique material that's not on a date of database we may be able to find a representative material as well as if you have certain properties you can actually add and do some custom materials especially if you're perhaps a material supplier manufacturer so in this case it's as simple as selecting the material we'll just leave the default here in this case we'll assume this is it and again you can just use whatever material is defaulted until you go back and identify what material is materials you will evaluate later the next step is as simple as selecting gates there's two options here under gates there's an automatic gate creation of course in this case we kind of know where the gates going to be we have a sprue and a run our system feeding the parks but the gate automatic gate creation is if you have a part and you're just not sure at this time you can select that auto generation and we can you have an option here for a number of gates and if your orientation in your part is not in a proper orientation you can see that this injection gate cone that is shown up it's easy to actually modify the pole direction to make sure it's in the proper orientation and then once you determine whether it's one gate or multiple multiple gates you can hit the calculate and it will calculate based on the projected area and some other mathematical calculations where the ideal or optimal gate location or locations would be dependent what you specified so again in this case we're not going to do the auto-generate we're going to actually assign our own gate so what we want to do is again go back into the kre-o interface we would want to orient this in a position to select the gate go back into the mold analysis select ad for gate we're going to select the top surface of the sprue and we have a diameter so this is going to actually simulate the nozzle tip and the injection mold and from experience we know that this is going to be a quarter inch diameter and obviously here we can make those those diameter specifications whatever we want within here select ok select clothes now what we need to do is the next step is to just go into analysis so we have the material that we assigned and again we have the option here if we want to change this material to anything else or just leave it as is for this case so I leave it on the default based on the calculations that the software is made for the geometry and the layout it's calculating that this should take 1.2 3 seconds this is just kind of some default and depending on the material it will make some other changes but from our experience you know you might know that this is going to require let's say one and a half second fill and it's very easy to make those changes in addition the melt temperature specifications these are default recommendations that come from the material manufacturer but again if you have experience or recommendations from your molder or your processing engineers we can easily tweak the melt temperature and the mold temperature temperature here as well we have the default maximum injection pressure limit it's not a bad thing to just go and increase this to twenty-five thousand psi as a rule of thumb a third area down here of optional simulations so depending on what you want to simulate and what level this is in the design process we can actually check these boxes which are by default or unchecked to calculate maximum cooling time and sync mark below that then we have our mesh element size again we have coarse mesh which is going to be a larger mesh size and it's going to produce a file that has less element counts we can go to medium so it's going to be a refined mesh there's going to be a larger element count in the file size and then we go to accuracy so again it depends on what you want to do at this point if we're just trying to check preliminary results or to try and identify the balance of the flow you know it's always and I found it with these that there's not a major difference in time requirements if we just start with the medium or accuracy but at this point again for time sake we're going to select a medium for the mesh quality we've reviewed everything we like the material the processing conditions we're not going to worry about secondary or additional simulation options we selected our mesh size and then it's as simple as selecting add and it tells us that if we want to make change of the gate position update the gate layout from the gate setup dialog box and then add additional analysis so it's just a note to tell you that you can make other changes later so we selected the add we have this analysis 0 1 we can easily actually select that double click it and change that name to something that's a little bit more descriptive in details in this case perhaps we want to say that this is analysis 0 1 we want to specify ABS as the material and this process condition 0 1 in the event that we want to make some changes later select okay you can actually at this point if we were to make changes we can make changes now and add additional analysis this we're not going to do at the moment we can check that box and then hit run analysis it's going to ask you again if you want to save the project and of course we want to do like everything you want to save and save often now you can structure this and put this in folders to where you want to have that saved if you want to organize this within your system not going to worry about that right now we'll go over some of that and other models that I'm going to show up shortly I hit save this pop-up window will start and I'm just going to keep this briefly so we can see how quick it goes through the meshing process and the estimated time that it's going to take to run the simulation which I'm estimating should be approximately 10 minutes and actually because we got through that step now I did run some previous simulation on this this part as is and we can actually jump right into those files now so we're going to go back and run through the process of retrieving the results files so we have our CAD model opened up in creo we select the applications button again we have our ribbon that displays all of our extensions select the mold analysis extension you know everything is grayed out here on the results and so to retrieve a set of simulation that you've already saved the project you select mold analysis files we want to retrieve project and then we want to in this case we locate where we've got that file at so we open up or select and open up this mold analysis extension and we can select the analysis tab and it shows the various analysis that we ran so we ran one with polycarbonate and of course we ran one with ABS and if we want to evaluate for whatever reasons we can actually select whichever file we want to to evaluate and they're completed with a checkmark indicated select activate clothes and once we do that we actually see that the results tabs are displayed they're no longer grayed out and we can evaluate various results now again in this case we're just tasked as this reasonable application or design to produce an acceptable parts and net1 material and one of the things that I use it for a lot especially in the up front is to evaluate the filling and the processing your pressures and your clamp tonnage requirements so if we take a look at this where I'm going to go through some of the results selecting the melt front time and we want to check and see if this is a balanced fill and what we have here is again once we select once we select various results some other options are available to us under the view control it gives us a couple options of clipping and slicing and we can actually clip and in check at a certain time step or a certain location in the simulation we can actually slice and move to look at an individual slice and this might have more valuable or value with a part that has additional geometry maybe bosses or ribs that you want to actually check and see it at that that segment or that stage in this case primarily one of the valuable tools is the animation so we select the animation we have a bar here that we can control the speed we actually hit and run through the animation great indication this took about ten minutes once we ran it and what we're indicating is there is an imbalance in the fill which would be expected because we've got two dissimilar parts and we are having an imbalance at young to 60% so the next thing we might want to check is some other results so like the pressure required we're indicating a PSI of over 24,000 psi and we might want to also then check the clamp tonnage requirement so this is predicting a 6,000 ton plus press and we know that we're gonna we need to run this in a smaller press so this is one of those indicators that perhaps this design or this material is not a suitable candidate um based on this design we can also then go we evaluated an alternate materials we have two candidates we are allowed to look at so we go to the ABS go through the processing I'm sorry of analysis select the analysis and hit activate and we can check the results here so obviously the melt front imbalance is going to be the same regardless we look at the pressures okay we've noticed a significant reduction in impression injection pressures as well as we can overlay and do the clamp tonnage so we've gone from a six thousand ton press to you know 450 ton press requirement but the thing is we're still not necessarily liking this design and we've been challenged to come up with a to evaluate other options to provide better better processing and again reduce and produce better quality parts and one of the concerns would be with this is we've got since the imbalance you've got your shears and your maximum shear rate and stress is within the parts that you may have some warping or other defects so let's step in and go to another analysis where we had the flexibility of looking at additional options so after we've evaluated whether it's by yourself independently or with the team to point out the concerns on the original design and we look at an option to simplify this tool and redesign the layout to eliminate that large through and that runner system and trying to balance out the part filling so we open up this or we've come up with this design collectively and again so we kind of run through the process and I'll run through that again on the steps to go through and set up this analysis we go back to the applications mold analysis we're going to retrieve a project we go to the file location that we've created it in and again I would just recommend at any time you're doing this stuff that you keep the mold analysis files maybe in a separate folder to easy retrieve so it doesn't get all you know bunched up with your CAD models so again we're retrieving this file I ran several analysis in here so we can kind of see the time selected the wrong file my apologies so again we retrieve these files and I'll go through the steps that we saw so we went through the whole process of analyzing this new layout perfect so as I step back here through the steps we we have this new design of the part we actually went through the steps of actually checking out in this case to see which is the what's the proper location or the gate of this new design where do we need to gate this new design and then evaluate the melt front advancements and the other results that are critical for an acceptable processing window and for quality of the part so we we went back in so we selected an injection location approximately in this location where it's indicated by red that's the first point of the material coming in so again the way I would use this is we would go through and check the animation so go select mil front time you control animation and we can run through the animation and just check to see how that balance fill what we're looking at as you can see graphics at least on my end appear to be very good I did notice right there we ran this we weren't sure the gate location we approximated it we actually selected the gate location run ran the simulation and again so we can just jump to the end and back this up until we can see the balance or imbalance in the filling okay so we're basically add like a 78 78% imbalance okay so this is a great indication we don't we have improvement in the balance to fill but we think we can make it better we also want to go and take a look at the pressure requirements so again with this material and this layout in that gate location our pressures are kind of high and again just to save time I ran various simulation in this case this application yes we've got the PC lexan which was requested as a possible candidate yeah we've gone through and I've got a gate location zero one I went and based on the simulation again that took about 10 minutes to process and give us the results went and did another layout modify the gate location a little bit more to do the same thing to evaluate you know pressures not a big improvement on pressures melt fronts again view controls animation would just start at the end and we'll just back up so we'll check the balance of Phil we still have an imbalance about 89% again just taking a few more moments and we went and we made another a third gate change location we can select that gate location activate close jumping to the milk front time advancement the view control and animation and start backing up so basically with this third date location and all this took less than 30 minutes we actually have an approximate gate location that would provide a more balanced fill of the part the product improvements in the injection pressure significant improvements and you know once you have that balanced fill and your lower pressures everything else your temperatures which are also included here that we can calculate that and that's something that might be required as you get further into the analysis and once you've really finalized the design to really evaluate those other results requirements so again so went through this process ran a gate location one two and then three and all this did was cost us a little bit of time and then once we have that actually finalized went through the process so we've got this part here went through the process of actually within your creo model adding geometry so went through and added a representative sprue and you know experience is going to see that you know typically we might want to have a dispersion disk added under this fruit if you can't do a cold slug because you want to actually do this it's a good practice to reduce the velocity as a material transitions from a sprue into the part so went through this process so this is a great do II I did some checking up front to identify based on the design as is you know where's the best gate location and then went through did a little bit more CAD modeling I'm added in some more detail and ran through that analysis and what we do is we'll go through again now once we have more detail identified we want to run and check the results here going to check the melt front time advancement again check the animation we're going to just confirm that still a balance Phil actually it looks like even that minor change with putting that screw in that dispersion disk has affected the fill a little bit but it's still it's a very good tool because it gets you much closer to that that general location that you would recommend for gay Deena obviously these results it's still a relatively balanced fill at 97% you could always go and run another one to tweak it but in most cases this is more than acceptable to pass this on take this design share it with the rest of the team and then send this out for quotes or evaluation and in this case yeah this is a tool this was used for whatever the requirement was you could have made multiple cavity tools of this a single but in this case it's a lower-cost tool for family you get both parts with one and the tool the Creole mold analysis extension allows us to evaluate these design changes early and often within the design process and again once we had the CAD model designed all these simulation and the design changes was done within about an hour now so we've done this evaluation and as we still have just a little bit more time you know this tool can also be used again to evaluate an existing tool that you've got so say you've got this tool this tool has been built and it is running a certain material but after it's been built and run there's some issues with the materials again so using the creo mold analysis extension we can actually do a do e to again evaluate the different materials that might be suitable candidates in this application again so originally this tool was built it was a Sabich lexan 9 for 5 activate and once the tool was built again we didn't do any advanced simulation early on the tool was built and we're looking at this results and we have opened here's a good point so the previous model we looked at was generated in English and so the results are in English this part was in metric so we're on the metric scale so depending on what you want to see the results in its you might want to make sure that the original creo file that you are using um is in the right units so we have in this material it's requiring 155 mega pascals and for whatever reason processing this was an issue and the OEM or that they have another candidate a material we want to evaluate and so again we basically duplicated that analysis we set up some parameters we process through that and again for this we would just want to see any improvements with the material so we went from 155 mega pascals to 85 mega pascals so again this tool is just a very powerful and easy and quick tool that can be used to evaluate gate locations whether or not you need a single gate multiple gates if you just had a part like say this part came in and no tool design was recommended and you just have this frame you could select we could go through the process and just put gate locations to evaluate the minimum amount of gates that would be required to fill this of course after that when you have multiple gates in that then you've got to worry about balancing the runner system so again this tool can be used very early on with no runner system or as we get further and a tool design is developed so like everything it's simulation it doesn't take a lot of time and the the money that it can save before a tool is constructed to have that direct interface within your creo parametric it's just such a powerful tool and to have it in-house a lot of times the designs will be done and you'll outsource that to somebody else and it takes time and that takes money and then you're doing all the interactive and all these iterations right there yourself so actually if with that said and we've gone through a couple different samples I guess we can take this and the demo and take this to see if there are any questions so also with that said you know here's our Q&A page here's my contact information John Hughes at Boundary sis comm and if there are any questions on this presentation or any of the products provided by and supported by boundary systems you can contact sales at Boundary systems.com also we have our YouTube channel and this webinar will be posted up in a couple of days back to the website so it's there to access to review let's see so do we have any questions oh yes sir the question is this extension included with every cRIO seat there is actually a stripped-down version that is included and I'll have to get the information it's limit enough on what it can do as far as the material database and if we go back into this we go back into these the the power of this tool is the materials that are provided Leia said it's over 6,000 materials and if you can't find the exact specific material you have here there are options to actually customize you can actually contact potential suppliers and they can actually provide they can provide the information necessary to generate your own custom material Hansol I want to say that right now yeah all these materials properties that are provided are provided by the manufacturer and again so these again it's just a powerful tool that can be used and should be used early and often and in the design process before you spend the time and money to have an injection mold design that may not produce what you want and then always the problem is afterwards is what changes can you actually make to that tool that will fix it and oftentimes they're very costly and/or the only other option is the tools been designed and the material we specified we didn't analyze it it will not process that tool as designed in that part so what are the materials can we look at and then of course we have to evaluate the shrink effects on the tool but again like everything analysis and nowadays is very cheap or inexpensive and easy to access and oftentimes in avoiding one mistake on a tool would more than pay for and justify that software so by chance is there any other further questions and again if there are any questions or that that come up later that you think of again please mark down my contact information and myself or anybody from boundary systems would be more than happy to address your questions and provide further information and I guess we'll just wait another minute or two and see if anything comes up and then if that's okay we'll end the webinar for today and I'll thank everybody again for your time and I hope that the presentation was well and you learned some stuff of the functionality and the value of the creo mold analysis extension okay with that said again thank you everyone for your time have a great rest of your day and week and hope everybody staying safe and healthy thank you

Channel: BoundarySystems

Views: 3,916

Keywords: creo, mold, pdsvision, boundary systems, ptc, cma

Id: FCizQ-k0IPE

Length: 39min 30sec (2370 seconds)

Published: Thu Jun 18 2020