Elastomer Processing: Simulation Helps Injection Molders to Maximize Revenues
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SIGMA Plastic Services, Inc.
10 N. Martingale Road, Suite 425
Schaumburg, IL, 60173
Press release date: September 7, 2012
Besides predicting the filling process, the process simulation software SIGMASOFT® can also predict the curing reaction of elastomers and the thermal performance of mold tempering systems. A major advantage is that not only the cavity is simulated, but the complete mold including all details is considered in the calculation. Therefore, the interaction between heating elements, elastomer, inserts and mold can be accurately predicted.
Schaumburg - In the elastomer processing industry, it is common for companies to rely on trial-and-error methods to solve production problems. Without process simulation, operators suggest a mold configuration which "should work" for a specific part geometry, based on experience. Factors such as tempering or processing times are defined later during the first production trials. It is not uncommon to find molds which require several rework stages, as well as parts with quality issues where the causes for this issues are not well understood.
Simulation technology can help avoid all these typical processing problems while saving significant time and effort during the development of a new mold. When utilizing the approach of "Process Simulation", provided by SIGMA® with its software SIGMASOFT®, all the elements of the mold can be included. This allows the molder to run a "virtual production", including all the process stages (preheating of the mold, injection, curing), not only over one cycle, but over several production cycles. With this process, the performance of a mold design can be evaluated completely before the steel is even cut.
"Historically, elastomer molders have relied on conventional injection molding tools to predict the filling of the cavity. Many processors still think this is all simulation can do for them. However, simulation tools available nowadays are far more powerful. Besides filling, the curing reaction can be accurately predicted, and the thermal behavior can be exactly anticipated", explains Dr. Marco Thornagel, executive director of SIGMA Engineering GmbH/Germany. "Simulation can make a company achieve its production goals faster, being more profitable".
Simulation can analyze different variables of the design of a new mold. After determining the desired geometry, the process starts with the selection of the injection point or gate type. Understanding the flow behavior, as well as quality issues related to weld lines, air gaps or jetting, the runner geometry can be defined. In this stage, different aspects including cavity balance or the pressure requirement can be predicted.
Once the part and runner are defined, the tempering of the mold can be designed. In the simulation the tempering elements can be precisely included: it is possible to define their exact location in the mold, as well as the material and the electric power. Even the control system can be defined. Instead of assuming a mold temperature in the simulation, the exact thermal condition of the mold is predicted, including the way it fluctuates over time.
After the effect of the desired tempering system is simulated, factors in the mold which can compromise part quality can be identified. Cold spots in the mold where the material cures too late or irregular temperature distributions, which can produce different curing degrees for parts produced in different cavities, are some examples of the virtual "troubleshooting" that can be achieved with Process Simulation.
For more information: Christof Heisser or Matt Proske SIGMA Plastic Services, Inc. 10 N. Martingale Road, Suite 425 Schaumburg, IL 60173 Phone 847-558-5600 Email firstname.lastname@example.org Web www.3dsigma.com
Agency Contact Wendy McCormick Bernard & Company email@example.com 847-934-4500 www.bernardandcompany.com
Figure 1 -Simulation can be used to support the complete mold design process. All elements in the mold are considered, so that an exact prediction of the processing conditions can save production time and troubleshooting effort.
SIGMA® (www.sigmasoft.de) is 100% owned by MAGMA® (www.magmasoft.de), the world market leader in casting process simulation technology based in Aachen, Germany. Our SIGMASOFT® process simulation solution optimizes the manufacturing process for injection molded plastic components. SIGMASOFT® combines the 3D geometry of the parts and runners with the complete mold assembly and temperature control system and incorporates the actual production process to develop a turnkey injection mold with an optimized process.
At SIGMA® and MAGMA®, our goal is to help our customers achieve required part quality during the first trial. The two product lines - injection molded polymers and metal castings - share the same 3D simulation technologies focused on the simultaneous optimization of design and process. SIGMASOFT® thus includes a variety of process-specific models and 3D simulation methods developed, validated and constantly improved for over 25 years. A process-driven simulation tool, SIGMASOFT®, with its comprehensive simulation approach, provides a tremendous benefit to production facilities. Imagine your business when every mold you build produces required quality the first time, every time. That is our goal. This technology cannot be compared to any other conventional "Design" simulation approach employed in plastics injection molding.
New product success requires a different communication between designs, materials, and processes that design simulation is not meant for. SIGMASOFT® provides this communication. SIGMA® support engineers, with 450 years of combined technical education and practical experience, can support your engineering goals with applications specific solutions. SIGMA® offers direct sales, engineering, training, implementation, and support, by plastics engineers worldwide.