Moldex3D Application in
Microcellular Injection Molding Development
SimpaTec Sarl
Fabien BUCHY
24.04.2013
SimpaTec
founded 1/2004
Reseller
since 2004 in Germany
since 2005 in BeNeLux
since 2006 in France, Swiss et Austria
Office at Guebwiller, Grenoble, Aachen, Stuttgart, Bangkok.
Since 10/2007 Beaumont Technologies Inc. reseller
SimpaTec - Focus
1. Services
Plastic injection simulation services;
Moldex3D distribution
Moldex3D support and training
BIMS seminar with Dr Vito LEO
2. Commitment
Research
Software development
Workshop, seminar
Partnership
Microcellular Foam Injection Molding
The Microcellular Foam Injection Molding is based on the control of
supercritical fluid (PBA) during the injection molding cycle to create millions of
micron-sized voids in thermoplastics.
MuCell is most well known commercial microcellular foaming injection process
registered and marketed by Trexel, Inc.
MuCell is a registered trademark of Trexel, Inc.
Microcellular Foaming Process
Three major steps: (1) formation of a uniform polymer-gas solution;
(2) cell nucleation;
(3) cell growth and shaping
SCF
introduction
mixing/diffusion
diffusion
thermodynamics
instability
Polymer
Two Materials
Two-phase
mixture
Two-phase
mixture
Single-phase
mixture
Microcellular
Foam
Reproduced from US patent No.5,158,986
Principle
Three major steps:
Near surface
(1) formation of a uniform
polymer-gas solution;
(2) cell nucleation;
(3) cell growth and shaping
Core
(3)
(2)
(1)
Foaming Fundamentals
Cell Nucleation
Formation of cell site driven by the pressure drop
Related to the cell number density
Cell Growth
Cell growth on cell site driven by the gas diffusion
Related to the cell size
Motivation and Objectives
True 3D approach to provide more accurate micro-structure fluid flow information.
Predict cell number density and cell size by considering the cell nucleation and cell
growth simultaneously.
Consider the interaction between cell development and melt flow during molding.
Consider the effect of cell structure to the part warpage.
Fundamental Theory
and CAE Method
Theory of Cell Growth and
Bubble Pressure
Radius over time
Bubble pressure and cell concentration
Theory of Cell Nucleation
Nucleation model
f0 and F are fitting parameters of bubble nucleation rate equation
nucleation commences when the bubble nucleation rate J(t) > Jthreshold
Output of Molex3D MuCell Simulation
Cell radius distribution (typically 5-100 microns)
Skin (as small as better)
Core
Cell number density distribution (typically,107 -109 [cells/cm3]
Skin (as less as better)
Core
http://www.forestprod.org/composites09pilla.pdf /
Output of Moldex3D MuCell
Simulation
Foaming quality: Micro cell sizes
Output of Moldex3D MuCell
Simulation
Foaming quality: Micro cell density distribution
Moldex3D MuCell:
Step by Step Tutorial
Create a New Project
Choose type as Microcellular injection molding when creating a new project
Simple Mode
Classic Mode
Process Settings (1)
In filling/packing setting, users can shut off nozzle by checking the box Nozzle is shut
off. This action can skip packing process and avoid reverse flow of melt during
foaming.
Process Settings (2)
Microcellular settings
three settings shown below: Foaming duration time, Start foaming setting, and
Initial Gas concentration.
Process Settings (3)
Foaming duration time
specify the holding time (sec) after filling to simulate the foaming process, which includes
cell growth and solidification.
Start foaming by (Control shot size)
If Nozzle is shut off is selected, nozzle is shut off at this starting time. Users can define
the starting time in terms of Volume filled (%) or Pre-injected volume (cm^3) as below.
Initial Gas Concentration
define the initial gas concentration in terms of Gas dosage amount (wt %) or Gas
saturation pressure (MPa) as below.
Computation Parameters (1)
Click the Advanced Options for filling/packing solver button in Fill/Pack tab to input the
parameters
Computation Parameters (2)
Four settings: Gas type, Bubble growth model, Material properties and Nucleation
parameters.
Note:
Parameters of N2/PP (Gas/polymer) are set as N2s
default value and CO2/PP as CO2s default value. If a
different Gas or polymer is chosen, user may modify
the material properties and nucleation parameters to
get an accurate result.
Gating Location Effect
Melt front animation
Gating from thick area
Gating from thin area
Case Study
Comparisons of Simulation and
Experiment of Position A
A
0.2 wt% N2 SCF dissolved in PP
40 m
Center ~ 40 m
Comparisons of Simulation and
Experiment of Position B
B
0.2 wt% N2 SCF dissolved in PP
40 m
Center ~ 50 m
Solid Shot Warpage
Production solid shot
Moldex3D Solid shot
Solid Shot - mm
Mucell Warpage - 0.5 wt%
Production - Mucell
Moldex3D - Mucell
0.5wt% - mm
DIGIMAT 5.0 Moldex3D Mucell
FEA
Measurements
Structural analysis
Material Model
stress
s/e curves
Workflow for Mucell part
structural
performance
evaluation
Volume fraction
strain
Mapping
Moldex3D / Mucell
Structural mesh
Data on processing mesh
copyright e-Xstream engineering 2012
Comparison (X10)
Solid
MuCell
Application example:
Warpage improvement
N2/PS
(Gas:0.5wt%))
Microcellular
Injection Molding
Filling time
0.70 sec
Tmelt
190
Tmold
60
Volume filled
90%
Melt Front Animation of
Microcellular Molded Part
Foam Properties of
Microcellular Molded Part
Size Distribution
(<45 m)
Cell Density of Microcellular
(~1.3 x107 [cells/cm3])
Cell Density
102 [cells/mm3]
Cell Radius
10-5 [m]
Dimensional Stability - X Displacement
Microcellular Injection Molding
Conventional Injection Molding
<0.1 mm
-0.2 ~ 0.2 mm
10
10
Conclusion
This study presents the 3D simulation capability of predicting dynamic behavior for
microcellular injection molding process.
Good quantitative agreement between simulation and experimental results are found.
In the industrial application, simulation results meet the criteria of prediction capability
for application on microcellular injection molding product.
R12 Support eDesign
R13 Support MuCell + Injection Expansion (Core-Back)
Acknowledge
Trexel Inc. for providing great information
Special thanks for Steve Braig (President) and Levi Kishbaugh (V.P.
Engineering)
Many thanks to Patrick Tong, GM of Trexel Hong Kong Limited
Prof. Lih-Sheng (Tom) Turng, at University of Wisconsin - Madison (UW)
For providing the experimental result and a lots of assistance in microcellular
injection molding study.
Interested? Talk to us:
SimpaTec Sarl
Fabien BUCHY
3 rue du Gnral de Gaulle
68500 GUEBWILLER
Tel: +33 3 89 82 45 64
Email: [email protected]
www.simpatec.com
