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With the process-oriented approach of SIGMASOFT®, the injection molding simulation for elastomers is no longer limited to predicting the cavity filling while designing the part, or to answering questions regarding balanced filling. Based on an accurate simulation of the curing reaction (vulcanization), it can be used for designing the mold, identifying process windows and troubleshooting during production.
SIGMA Plastic Services, Inc., Schaumburg, IL presents the latest functionality of its 3D Injection Molding Simulation Software SIGMASOFT®. The focus is on reduction of development and production costs using these new developments in process simulation.
Many factors in elastomer injection molding have an influence on product quality and costs. Here it is of little help to solely focus on a single aspect; part design, material, mold design, or molding process. To ensure a competitive advantage, the entire system must be considered simultaneously. Only when everything is optimized during the design phase, before the mold is shipped, can the largest cost savings be achieved.
By means of process simulation, molding feasibility and initial process parameters can be evaluated. Parting line and venting channels can be developed, as well as the optimal type and position of the injection point. Where are weld-lines acceptable, where must they be avoided? How much injection pressure will be required? Ultimately, the complete mold and process must be optimized. What wattage and heater design is most beneficial? Where is the best thermocouple location for each heater? Do inserts need pre-heating and how will they influence the curing? How long is the curing cycle, what areas of the part cure late and why? These questions are all related to the mold design and the production process and they are all important factors regarding part quality.
The simulation results provide answers to all of these questions in a clear and meaningful way, allowing injection molders a way to virtually test the mold before it is built. Costs can be reduced significantly during development, and existing processes can continuously be improved, while substantially reducing material waste and improving quality.
The latest developments in the thermal solver allow for the integration of all mold components and their individual temperature dependent material properties. In this way, an accurate reproduction of the real temperature profile in the mold is possible, even over several consecutive injection molding cycles. The simulation set-up is optimized for the requirements of process engineers. This allows production-minded engineers to use this technology without a simulation background. For example, a process engineer can determine how heating cartridges influence mold temperature and part quality, simulating them with their respective electric power and thermocouple control.
For more information:
Christof Heisser or Matt Proske
SIGMA Plastic Services, Inc.
10 N. Martingale Road, Suite 425
Schaumburg, IL 60173
SIGMA® (www.3dsigma.com) is 100% owned by MAGMA® (www.magmasoft.com), 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, thermoset, rubber, and MIM/CIM 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.