Real World LSR/Silicone Part & Mold Evaluation

Real World
LSR/Silicone Part & Mold Evaluation
From mold filling and part curing to mold temperatures over an
entire cycle, state-of-the-art simulation considers every
technical detail of the injection molding process. Yet, the
complete potential of simulation is often not turned into full real
world value. That is, until now. What are real world LSR
simulation applications?
Torsten Kruse
Kruse Analysis
1050 Borghese Ln. Suite 806
Naples, FL 34114
Tel: 239-353-6468
Email: [email protected]
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Simulation Capabilities
• LSR Simulation Capabilities
Filling Pattern Evaluation
Thermal Mold Evaluation
Curing Evaluation
Simulation Capabilities
• Consideration of the entire mold and the entire production cycle
• Temperature simulation is based on the 3D Fourier Law, filling
simulation is based on the 3D Navier Stokes Equation
Fourier’s law:
Navier Stokes Equation:
Roembke Mfg
& Design, Inc
Grommet / Matte Seal
LSR-Simulation
Grommet Mold Model
Roembke Mfg
& Design, Inc
Grommet Mold Fill-Time
Roembke Mfg
& Design, Inc
Grommet Mold Fill-Temperature Cycle 1 Roembke Mfg
& Design, Inc
Grommet Mold Fill-Temperature Cycle 5 Roembke Mfg
& Design, Inc
Grommet Curing Cycle 1
Roembke Mfg
& Design, Inc
Grommet Curing Cycle 5
Roembke Mfg
& Design, Inc
Grommet Curing Temperature Cycle 1
Roembke Mfg
& Design, Inc
Grommet Curing Temperature Cycle 5
Roembke Mfg
& Design, Inc
Grommet Curing % Cycle 5
Roembke Mfg
& Design, Inc
MR-Mold / LSR Suction Cap Mold
MR-Mold / LSR Suction Cap Mold
MR-Mold / LSR Suction Cap Mold
MR-Mold / LSR Suction Cap Mold / Model
MR-Mold / LSR Suction Cap Mold / Shear Rate
MR-Mold / LSR Suction Cap Mold / Fill Time
Simulation Capabilities
Details considers in the simulation:
– Part
– Cold runner
– Mold plates
– Insulation plates
– Valve gate needles
– Heaters
– Cooling Lines
–…
20
Simulation Model
Moveable Mold Half / Nozzle Tip
Stationary Mold Half
Insulating Pate
Cold Runner Body
Nozzle Body
Cold Runner Cooling
Heater
Inlet / Hot-Runner
Part / Cold-Runner
Insulating Air
Inserts
Filling Pattern Air Entrapments
Air Bubble
Process Setup
• Simulation of 11
cycles to achieve a
quasi stationary
mold temperature
• Filling with time
dependent flow rate
Initial material
temperatures
Mold Temperature Development over 10 Cycles
• Mold heating over 10 cycles
• Impact of heater positions to the mold temperature
• Heating channels
Impact Mold Material to Mold Temperature
• Left Insert is made out of steel, right insert is made out of copper alloy
• More homogeneous insert temperature with copper alloy
• Better heat transfer
Common mold steel
Copper alloy
Start cycle
End of cooling phase
Impact of Insert Material on Curing Reaction
Steel Insert
Copper Insert
• Better heat flow from the mold into the part due to copper
alloy leads to a faster curing reaction
• Inner areas of the part are curing slower and a second
heating cycle is required
Nozzle Temperature Causes Pre-Curing
• Insulation between hot mold and nozzle tip does not
work efficiently
• Temperature is too high and initiates curing reaction
inside the cold runner nozzle
Evaluation Cycle Time and Curing Reaction
• Color Scaling:
– Blue - curing reaction
not yet started
– Red – Curing
reaction started
• X-Ray Function hides
cured areas
• Part curing time:
about 80 seconds
2nd Heating Cycle – Impact of Oven Temperature
Curing Reaction
• Improved temperature profile avoids over curing
• Improved temperature profile does not lead to a different part curing
2nd Heating Cycle – Temperature & Curing
Conclusions
• Simulation helps
–
–
–
In internal and external discussions
In product/process development
Trouble shooting
• Simulation pays for itself
–
–
Direct ROI for project
Long term benefit through lean manufacturing
• Think about it!
How simulation will change your product
development and production?