Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Using the process-oriented approach of SIGMASOFT® makes it possible to consider all of the molding times present in an actual injection molding cycle. In the injection molding simulation of elastomeric applications, SIGMASOFT® not only considers the filling and curing times, but also the non-productive times between each production cycle while the mold is opened and closed. If the simulated process considers the influence of multiple consecutive molding cycles, the accuracy of the simulation is dramatically improved.
Figure 1 – Temperature distribution in a metallic component over-molded with rubber. Left: without consideration of the mold opening time; right: considering a mold opening time of 60 seconds, where significantly lower temperatures and long curing times are observed.
Even though it is not necessary to include them to complete an injection molding simulation, the “non-productive” times have a major influence on the mold temperature and thus on the process and on the part quality. With the Process Simulation Software SIGMASOFT®, from SIGMA Plastic Services, Inc. (Schaumburg, Illinois), all the non-productive times can also be included into the simulation of multiple consecutive production cycles and a substantial improvement in the accuracy of the results predicted can be achieved.
Considering the times in which the mold opens and closes, the times in which the mold is heated or cleaned, as well as handling times in which the inserts are placed or the parts removed, makes it possible to exactly describe the real multi-cycle production process. The interaction between all components present in the mold is considered with the local temperature dependent material properties, along with the heat that escapes the mold into the environment while it is both opened and closed and the exact timing of each event are coupled together inside of SIGMASOFT® to provide a comprehensive understanding of a very complex system. In this way, even factors that influence the part quality, such as the mold temperature and curing degree, can be predicted before the mold is ever built.
An example is presented in Figure 1. In this case, the mold temperature drops significantly while it is in the open position because heat radiates from both heated mold surfaces. If this time and open condition are not considered in the simulation, the mold temperature calculation will be higher than actual; resulting in a faster curing reaction and a shorter cycle time than what is actually possible. Other events will also be incorrectly calculated such as curing degree during filling and required injection pressure.
In SIGMASOFT®, non-productive times can be defined and individually modified in the simulation. For this reason, it is also possible to optimize the entire production process or mold design simultaneously. Through this simulation, it is possible to decide if changes in the process definition will solve production problems, or if the mold has to be modified to achieve the desired quality and productivity goals.
For more information:
Matt Proske
SIGMA Plastic Services, Inc.
10 N. Martingale Road, Suite 425
Schaumburg, IL 60173
Phone: 847-558-5600
Email: contact@3dsigma.com
Web: www.3dsigma.com
—
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.
Continue readingWith 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.
Figure 1 – The process-oriented approach of the Injection Molding Simulation Software SIGMASOFT® allows all relevant information (Part, Insert, Venting, Material, Mold, Heaters, Thermocouples, Process, etc.) to be used in the calculations.
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
Phone: 847-558-5600
Email: contact@3dsigma.com
Web: www.3dsigma.com
—
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.
Continue readingBesides 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, September 7, 2012 – 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: contact@3dsigma.com
Web: www.3dsigma.com
Continue readingThe process-oriented approach of SIGMASOFT® makes it possible to use injection molding simulation of elastomer applications not only for filling or cooling times, but also the non-productive times between each process phase. When the process is simulated considering the influence of operational times occurring between the main process stages, the accuracy of the simulation is dramatically improved.
Temperature distribution in a metallic component overmolded with elastomer. Left: without consideration of the mold opening time; right: considering a mold opening time of 60s.
Schaumburg, IL, September 7, 2012 – Even though it is not necessary to include them to complete an injection molding simulation, the non-productive times have a major influence on the process and on part quality. Process Simulation Software SIGMASOFT®, from SIGMA®, can include non-productive times in the simulation enabling substantial improvement in the accuracy of the results to be achieved.
Taking into consideration the times in which the mold opens and closes, the times in which it is heated up or cleaned, as well as handling times when the inserts are placed simulation makes it possible to accurately analyze the process cycle. The interaction between all mold components has to be considered and cycle times have to be predicted accurately. That way even factors that influence the part quality, such as the curing degree, can be predicted by the simulation.
An example is presented in Figure 1. In this case the mold temperature decreases during the time period when the mold stays open. If this time is not considered in the simulation, the prediction of the whole cycle time, as well as the prediction of the cooling time or curing degree, will be erroneous. Besides, the predicted quality of the parts produced can deviate from reality.
In SIGMASOFT®, such non-productive times can be defined and varied separately in the simulation. Therefore, besides calculating the whole cycle, it is also possible to perform trouble-shooting of problems at each of the production stages. Through the utilization of simulation it is possible to decide if changes in the process definition are enough to solve production problems, or if the mold has to be reworked to achieve the desired quality and productivity goals.
—
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.
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: contact@3dsigma.com
Web: www.3dsigma.com
Continue readingThanks to a completely reengineered solver technology and a revolutionary meshing concept, with SIGMASOFT® Version 5.0, the simulation time required in elastomer applications can be reduced by up to 80%. With this dramatic speed-up, simulation can now be integrated in the elastomer processing on a daily-basis, both for part design and process troubleshooting.
Figure 1 –With the new solver technology and the use of “unstructured meshes,” SIGMASOFT® Version 5.0 reduces the calculation time by up to 80% in the simulation of elastomer injection applications.
Schaumburg, IL, July 25, 2012 – At the DKT conference in Nuremberg, Sigma Engineering GmbH, Aachen, presented SIGMASOFT® Version 5.0, the latest release of its process-oriented simulation software. With a completely reengineered solver technology and a new meshing concept, calculation times have been dramatically reduced, while keeping all the advantages of accuracy and user friendliness of a complete 3D-simulation approach.
“With SIGMASOFT® Version 5.0, we have achieved a major breakthrough in injection molding simulation,” explains Dr. Marco Thornagel, Executive Manager at Sigma. “Some years ago, users had to wait sometimes days to get the results of a simulation. It was not viable to use simulation to support every-day production activities, or to quickly optimize products. Now, however, simulation can be part of the daily production tools used in the mold shop or in the production floor, to deliver reliable and profitable answers both to design new products and to optimize existing molds.”
SIGMASOFT® is still the only option available in the market to seamlessly integrate all elements in the mold within the simulation. Thanks to the implementation of “Finite Volume” numerical methods, not only can the cavity be considered in the simulation, but also the complete real mold configuration, including tempering channels, heating elements and inserts. SIGMASOFT® is and has always been based exclusively in 3D technology, developed over a quarter century. The mesh required to conduct the simulation is generated effortlessly by the user in only minutes, without requiring any manual optimization.
The new meshing technique in the latest version of the software uses “unstructured meshes.” These are basically “intelligent meshes,” which can automatically mesh finer regions where complex thermal and flow phenomena take place, such as part boundaries, thin walls or complex runner systems. It also can save mesh elements in regions where fewer interactions take place, such as mold boundaries. The calculation effort is reduced and the productivity of the software increases.
Through parallelization, the new solver architecture makes it possible to exploit the complete potential of multi-core technology in state-of-the-technology computers. Beyond a significant reduction in computational time, the technology now allows users to simulate more complicated injection molding processes. This will be now the focus of further developments in the software, according to Sigma sources.
For further information on this story, please contact:
Matt Proske
SIGMA Plastic Services, Inc.
10 N. Martingale Road, Suite 425
Schaumburg, IL 60173
Phone: 847-558-5600
Email: contact@3dsigma.com
Web: www.3dsigma.com
Continue reading
Schaumburg, IL. — SIGMA Plastic Services Inc. has donated SIGMASOFT® polymer process simulation software to Penn State Erie’s School of Engineering at Penn State Erie, The Behrend College, a gift valued at $3.7 million.
With this software, the campus has new technical capabilities for its soon-to-open Medical Plastics Center of Excellence and current Medical Plastics certificate program, two initiatives that address the emerging medical plastics market.
The U.S. market for medical plastics is growing at a rate of 5 percent to 10 percent annually and sales are projected to reach $6.55 billion in 2012.”Thanks to SIGMA Plastic Services, our students and faculty members will be able to develop the next generation of medical devices. This is a great partnership between academia and industry that ultimately benefits our students,” said Ralph Ford, director of the School of Engineering.
The $3.7 million gift supports Penn State Behrend’s goal of raising $32 million during the University’s current capital campaign, For the Future: The Campaign for Penn State Students. To date, the college has secured 81 percent of that goal.
Penn State Behrend’s Medical Plastics Center of Excellence is an applied research and outreach center that supports companies in the development of new medical devices and packaging, technologies that could not exist without advanced plastics materials. SIGMASOFT® software, designed for the molding of advanced elastomer, silicone and thermoplastic materials, supports these technologies.
Students enrolled in the Plastics Engineering Technology bachelor’s degree program can pursue the Medical Plastics certificate. The 14-credit certificate program prepares graduates for careers in medical product development with courses in advanced materials, new product design, manufacturing, and FDA regulatory issues. Nationwide, this is the only medical plastics certificate or degree program offered at the undergraduate level.
“Students will acquire in-depth knowledge of SIGMA products and will be better prepared to put what they have learned into practice after graduation,” said James Chiamardas, president of TPStek. “This is the first gift of SIGMASOFT® to a college or university in the United States. We’re pleased to work with Penn State Behrend on this important initiative.”
James Chiamardas, a Penn State Erie plastics alumnus and Erie native, played a key role in securing the gift. Chiamardas earned his associate and bachelor’s degrees in Plastics Engineering Technology. He is president of TPStek, LLC, a SIGMASOFT® reseller.
TPStek will provide technical support for the software, which is included in the value of the gift.
Christof Heisser, President of SIGMA Plastic Services, Inc. says, “We are happy to provide the School of Engineering at Penn State Erie, The Behrend College, with 25 seats of SIGMASOFT®, thereby giving students access to state-of-the-art Polymer System Simulation. Simulation has revolutionized the manufacturing world in the last 25 years and has become an integral part of the manufacturing process. It is, therefore, essential to integrate this technology into the education of the next generation of engineers and we at SIGMA are proud that one of the leading universities in the manufacturing world has decided to work with our simulation tool.”
SIGMA Plastics Services is in Schaumburg, IL. Located outside of Chicago, SIGMA Plastics Services Inc. is part of SIGMA Engineering GmbH, headquartered in Aachen, Germany. SIGMA provides 3D Polymer System Simulation software and engineering solutions to companies throughout the world.
For further information on this announcement, interested parties should contact: SIGMA Plastic Services, Inc. 10 N. Martingale Road, Suite 425 Schaumburg, Illinois 60173 USA
Phone: +1 847 969 1001 x 225 Email: cheisser@3dsigma.com Web: www.3dsigma.com Attention: Christof Heisser, President
Agency contact for SIGMA: Wendy McCormick Bernard & Company Palatine, Illinois (Chicago) USA +1 847 934 4500 wendy@bernardandcompany.com
Continue reading