2008 Int ANSYS Conf Plactic Injection Molding

2008 International
ANSYS Conference
Plastic Injection Molding Using ANSYS
Sarah Luo Ph.D.

Senior. Mechanical Engineer
Aurora Optical Inc.
2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved.
Daniel Robinson
Senior Consulting Engineer
PADT Inc.
AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
OUTLINE
Introduction
Issue
Assumption
Approach
Simulation Results
Conclusions and Future Work
Aurora Optical Inc. Introduction

A Quality Picture Worth
a Thousand Words
AO produces a wide range of camera modules,
including FPC or socket based, Ultrathin, Macro,
and Auto-Focus - custom module design is our business!
Camera Module Applications:
Personal Security Systems

Embedded PC Cameras
Mobile Phones
VoIP Phone Systems
Wireless Devices
Consumer Electronics
Medical Applications
Automotive Optical Systems
PADT Intro We Bring Dimension to Your Ideas

PADT is an Engineering Services Company
Mechanical Engineering
Design
Simulation
Manufacturing
Issue:
A plastic part has larger shrinkage rate than steel parts during
manufacturing. This is a major issue for our precision plastic
parts.
An example of a plastic part with shrinkage over 7~10 m during cooling
Factors
Plastic Part Shrinkage varies depending on:
Geometries
Material Properties
Process Parameters
Advantages
Plastic injection molding process simulation provides:
Shrinkage prediction for tooling compensations to

produce parts with best precision
Information for optimization, which can produce
parts with minimum shrinkage and shortest cycle
time
Simulation Modeling
The simulation models a completed plastic injection molding
cycle:
Air
Packing and Holding
Mold Cooling
Ejection
Gate
Freeze-off
Injection
Closing Mold
T(C) / P(MPa)
Cooling
t (s)
Temperature/ pressure vs. Time during a cycle

Packing Pressure (Given)
Gate Temperature (Given)

Part Temperature
Part Pressure
Approach
Plastic Injection Molding Simulation
Resin Material Properties
Plastic Injection Molding
Process Parameters
CFX-Mesh
3D Model
Workbench
CFX
Solid Material Properties

Boundary Conditions
Mesh
Thermal Transient Analysis
T (x,y,z,t)
CFX Convection Load
T(x,y,z,t)
Static
Analysis
P (x,y,z,t)
Volume Fraction (t)
Delta x, y, z
Shrinkage Profile
Multiphysics
Assumptions
Polymers:
1. Amorphous
2. Non-fiber reinforced
Known Input:
1. Process parameters
2. Gate temperature vs. time measurement data
3. Material properties
10
PVT Diagram for Amorphous

Polymer Modeling
Five stages at PVT diagram:
1
Injection phase: A-B
Polycarbonate
0 MPa
Packing/Holding phase: B-C

Gate Freeze-off and in-mold
cooling phase: C-D
Ejection parts: D
Specific Volume (cm3/g)
0.95
0.9
100 MPa
Tg
D
0.85
Outside mold cooling phase: D-E
Tg
0.8
0
100
200
300
400
Temperature (C)
11
Injection Phase
CFX Simulation Results:
Injection flow
Temperature
Pressure
12
Packing/Holding Phase
Volume Fraction
Temperature
Pressure
13
Gate Freeze Phase

Temperature
Pressure
14
Transient Results of the In-mold

(Cured) Cycle
Transient Temperature
at the part center
Transient Pressure
at the part center
15
Cooling after Ejection

Thermal transient analysis shrinkage results
16
Shrinkage Data in Multiphysics
The shrinkage data are exported to Excel for

shrinkage contour plots
17
ANSYS results vs.

Measurement Results
Shrinkage Predicted by ANSYS
Measured Shrinkage*
* The data were provided by Process Engineer Rick Culler
18
An Example of a Finished part using

ANSYS Shrinkage Compensation
Dimension Deviationactual-nonimal < 1m !
Measurement data after tooling compensation predicted by ANSYS*
* The data were provided by Process Engineer Rick Culler
19
Process Optimization
ANSYS Design Explorer
Six-Sigma tools
Design of Experiments
performed to optimize
mold temperature,
deformation, stress
20
Design for Six-Sigma
Input Parameters
- Inlet temperature
- Mold wall convective film coefficient
21
Six-Sigma Analysis - Distributions
Output Parameters
- Temperature
- Directional deformation
- Von Mises Stress
22
Design Points 3X3 DOE
Parameters varied
block factorial
design, in order to
characterize the
design space
23
Response Charts Design Space
Response Parameters
- Maximum deformation
- Maximum Von Mises stress
24
Min/ Max Values Output Parameters
25
DFSS Study Summary

Parameters varied were mold inlet temperature, mold to
Lexan convective film coefficient for cooling
Design of Experiments performed to examine effect of
these parameters on cooled solid part deformation,
maximum stress.
Results show for inlet temperature = 240F (design point)
hf = 5.895 Btu/hr-ft2-F
maximum residual stress = 61.6 psi
26
Conclusions and
Future Work
ANSYS results provide accurate shrinkage compensation
for tooling.
Future work includes non-amorphous, fiber-reinforced
polymer injection molding simulation, gate/runner
optimization etc.
27
Acknowledgements
A special thank to Arnie Sen, Raymond Hsiao, George

Kelly, and Dave Fredley for their consistent support of the
project. Also thanks Rick Culler for providing shrinkage
measurement data.
28
Questions and Answers
Thank you!
29

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2008 International

Sarah Luo Ph.D.

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

Aurora Optical Inc. Introduction

Camera Module Applications:

Personal Security Systems

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

PADT Intro We Bring Dimension to Your Ideas

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

An example of a plastic part with shrinkage over 7~10 m during cooling

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

Shrinkage prediction for tooling compensations to

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

Temperature/ pressure vs. Time during a cycle

Gate Temperature (Given)

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

Solid Material Properties

Thermal Transient Analysis

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

PVT Diagram for Amorphous

Injection phase: A-B

Packing/Holding phase: B-C

Specific Volume (cm3/g)

Outside mold cooling phase: D-E

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

Gate Freeze Phase

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

Transient Results of the In-mold

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

Cooling after Ejection

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

Shrinkage Data in Multiphysics

The shrinkage data are exported to Excel for

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

ANSYS results vs.

Shrinkage Predicted by ANSYS

* The data were provided by Process Engineer Rick Culler

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

An Example of a Finished part using

Measurement data after tooling compensation predicted by ANSYS*

* The data were provided by Process Engineer Rick Culler

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

Design for Six-Sigma

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

Six-Sigma Analysis - Distributions

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

Design Points 3X3 DOE

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

Response Charts Design Space

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

Min/ Max Values Output Parameters

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

DFSS Study Summary

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

A special thank to Arnie Sen, Raymond Hsiao, George

AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary

Questions and Answers