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Cadmould Flex-it! package includes:-
CADMOULD Flex-it! plastic flow software enables you to quickly view results from simulating the filling of the injection moulding process and to see the effect of cooling, warping and more. Cadmould Flex-it! includes Fill, Batch PLUS: Pack, Fiber, Warp, Cool, 2K & Insert and Cascadic Injection PLUS: Unwarp, T-Box, Injection Compression, Foam and Structural FEM. Flex-it! is available in two monthly rental packages:-
OPTION 1 : FILL module available for daily use, paid for on monthly rental basis, with ALL Cadmould modules (as listed above) available for 1 day per month.
OPTION 2 : ALL Cadmould modules (as listed above) available for daily use, paid for on monthly rental.
Cadmould FILL helps you to simulate the filling phase of your component, and calculates the results in 3D, as a cross section, and as an animation across time.
• Filling of the part
• Pressure distribution
• Temperatures
• Flow speeds
• Clamping forces during filling (for clamping forces in the holding pressure and cooling phase, the PACK module is additionally required)
• Forces on sliders during filling
• Weld lines
• Air inclusions and venting
• Cooling time estimation and shot volume
Benefits
• Optimal design of the part filling
• Optimized design of hot and cold runner systems
• Determine suitable gating positions automatically, and balance gating systems
• Adjust gating systems, as well as part wall thicknesses, directly in CADMOULD, without needing to go back to CAD
• Design multiple-cavity molds
• Achieve a better first-time right rate, reducing sampling time and material waste, since the parameters of the filling phase are already known and optimized. Reduce costly mold corrections. This results in significant time and cost savings.
• The simulation results enable you to discuss options, advantages and disadvantages with your customers and colleagues
Cadmould BATCH allows you to run multiple simulations in batch mode while you can focus on other tasks. This means you don’t need to trigger each simulation individually, but can “send off” several simulations at once. These are then automatically placed in the queue for the simulation calculation. Usage: After setting up various simulations, you can prioritize them in a task list. After you trigger the first simulation calculation, all further simulation jobs are processed automatically, according to the defined list.
Cadmould PACK enables simulation of the holding pressure and cooling phase of your component, building on the filling phase results from CADMOULD Fill. It computes the following results:
• Pressure distribution
• Temperatures
• Clamping forces
• Surface layer thickness
• Melt core in cross-section
• Volume shrinkage
• Thickness shrinkage / sink marks
• Cooling time and shot volume, incorporating the influence of the packing phase
Benefits
• Optimally specify packing pressure, clamping force, and cooling phase parameters
• Reliably determine freezing, sealing and demolding times
• Achieve uniform volume shrinkage distribution over the molded part
• Avoid sink marks
• Reduce part warpage through optimized shrinkage compensation (calculation of shrinkage and distortion results also requires the Warp module)
• Analyze temperatures and pressures to ensure reliable demolding
• Determine key data for part and tool costing by determining an optimized packing pressure and cooling phase with the software
• Optimize existing processes to achieve shorter cycle times, or in order to enable switching to a different injection molding machine
Cadmolud FIBER is an ideal complement to the Fill (simulation of filling), Pack (simulation of holding pressure and cooling phase) and Warp (simulation of shrinkage and warpage) modules. Cadmould FIBRE allows you to simulate the fiber orientation in your part. It calculates detailed results across time, and displays them averaged over the wall thickness, or in different layers:
• Fiber orientation direction
• Degree of fiber orientation
Benefits
• Precisely simulate fiber orientation direction and degree of fiber orientation
• Take into account fiber-related anisotropy when computing shrinkage and warpage2
• Solve warpage issues through the analysis of fiber orientation. Warpage can then be reduced through optimized gating points, wall thicknesses and process parameters2
• Export fiber orientation results to other software, e.g. FEM structural solvers, crash testing simulations, or acoustic engineering applications
Cadmould WARP is an ideal complement to the modules Fill (simulation of the filling phase), Fiber (fiber orientation) and Pack (simulation of the packing and cooling phase). WARP enables you to simulate shrinkage and warpage of any geometry. It computes the following results:
• Shrinkage
• Warpage
• Deformation
• Stress states (including frozen residual stresses)
• Temperatures after demolding
Benefits
• Precisely anticipate shrinkage and warpage
• Solve warpage issues by optimizing process parameters, adapting the mold design or changing wall thicknesses
• Use precise virtual measurement tools, to check compliance with dimensions
• Reduce sampling and waste, since warpage can be optimized beforehand
• As a result, better first-time right ratio and reduction of costly tool corrections. This results in significant time and cost savings
• The simulation results enable you to discuss options, advantages and disadvantages with your customers and colleagues
Cadmould COOL allows you to thermally design your mold and is the ideal complement to the Fill, Pack and Warp modules (simulation of filling, holding pressure and cooling phases, and of shrinkage and warpage). It computes detailed results concerning wall temperatures and the temperature control system:
• Number of cycles to the thermally stable state of the mold
• Local variation of cavity wall temperatures during the entire cycle
• Flow rate and pressure loss in the temperature control system
• Temperature change of the tempering medium
• Turbulence of the flow
• Temperature control efficiency
• Note: For full mold (as opposed to just cavity and cooling system) thermal simulation, also see our module T-Box
Benefits
• Optimal design of wall temperatures in the mold
• Safe design of temperature control systems
• Reduced sampling and less waste, as cooling times are already known and optimized
• Design cooling systems, without needing to go back to CAD
• Detect and eliminate hot spots due to mass accumulation or heat transfer processes in the mold
• Optimize cooling systems that are already in use, by determining optimal process parameters
• Reduce cycle times by optimizing the thermal system for the part and process
• Determine optimal cooling times
• As a result, better first-time right rate and reduction of costly mold corrections. This results in significant time and cost savings
• The simulation results enable you to discuss options, advantages and disadvantages with your customers and colleagues
enables you to simulate two-component and multicomponent parts. You can simulate parts that are produced by sequentially injecting different thermoplastics against each other, as well as parts with inserts made of different materials (such as metal). If these are techniques you use, then 2K & Insert represents an ideal complement to the modules Fill (simulation of filling), Pack (simulation of packing pressure and cooling phase) and Warp (simulation of shrinkage and warpage). 2K & Insert computes the following results:
• Filling of the part (with multiple materials / with inserts)
• Pressure distribution
• Temperatures (also inside the components)
• Flow speeds
• Deformation of inserts or core shift during the injection phase (in combination with the Structural FEM module)3
• Weld lines and air inclusions
• Freezing, sealing and demolding time
• Shrinkage, for 2K or insert parts
• Warpage
• Deformation
• Mechanical stress (including frozen residual stresses)
Benefits
• Optimally design multi-component processes
• Determine and optimize the thermal and mechanical influence of individual
components on the part
• Detect and eliminate filling problems in multi-component parts (air inclusions,
weld lines, etc.)
• Solve shrinkage and warpage issues in multi-component parts
• Identify ways to reduce the total warpage of multi-component parts
• Specify cycle times and optimal preheating temperatures of inserts
• Reduce sampling and waste, since the process parameters are already known
and optimized
• As a result, get a better first-time right rate and reduce costly mold corrections.
This results in significant time and cost savings
• The simulation results enable you to discuss options, advantages and
disadvantages with your customers and colleagues
CADMOULD Cascadic injection builds on CADMOULD Fill (filling simulation) and Pack (needed for packing pressure and cooling phase simulation).; it enables you to simulate cascade injection molding, and computes the same key results as the core CADMOULD modules, but with the capability of simulating sequential filling across multiple gates:
• Filling (including weld lines and air enclosures)
• Pressure distribution
• Temperatures
• Flow speeds
• Clamping forces
Benefits
• Optimal design of component filling by cascade injection molding
• Determine optimal cascade timing and gate switching criteria
• Determine the maximum injection pressure and identify ways to reduce this pressure by modifying the gate control schedule
• Compute packing and cooling phase results, as influenced by the gate control. Anticipate shrinkage and warpage (requires modules Cool and Pack)
• Anticipate and fix filling problems such as air inclusions, weld lines, etc.
• Rapidly and easily compare alternative gate control schedules. Discuss advantages and disadvantages with your customers
• Optimize process parameters for existing parts and molds, to reduce the maximum injection pressure, to optimize weld line positions, and to minimize warpage
Cadmould UNWRAP helps you to devise mold corrections for warpage compensation, in order to eliminate shrinkage and warpage. To achieve this, Unwarp uses the shrinkage and warpage results from the Warp module as inputs. The results that are computed include:
• Mold corrections for shrinkage compensation
• Mold corrections for warpage compensation
• Deformation corrections
• Deformed part geometries
Benefits
• Precise computation of mold compensation
• Maximum dimensional accuracy through optimal tooling
• 3D-print physical representations of deformed component geometries, to assess dimensional compliance and compatibility with connecting parts
• Better shrinkage and warpage results from the start, because they have been compensated for adequately. As a result, better first-time right ratio and reduction of costly tool corrections.
Figure 20: CADMOULD Unwarp displays the necessary mold compensation for shrinkage and warpage. The original part geometry is shown in grey. Orange areas signify compensated parts of the mold. The compensated mold can be exported in suitable CAD-compatible formats (tessellated, suitable for reverse engineering, see details below).
• The ultimate result: significant time and cost savings, and an enhanced ability to discuss options and their advantages and disadvantages with your customers and colleagues
Formats
You can view the results in CADMOULD, and export the computed warpage compensations, as well as deformed part geometries, for further use elsewhere. The following output formats4 are supported by our integrated export tool:
• STL (.stl)
• STEP (.stp / .step)
• IGES (.igs / .iges)
• Parasolid (.x_t / .xmt / .x_b / .xmt_txt)
• PRC (.prc)
• JT (.jt)
• UNIVERSAL3D (.u3d)
• VRML (.vrml)
• OBJEKT (.obj)
• COLLADA (.dae)
• Unwarp also enables you to create text files with displacement vectors, for example for working with CATIA® RSO®.
• In addition, it is also possible to view the geometries in HTML and 3D-PDF formats.
CADMOULD T-Box enables the thermal design of your mold. For this purpose, the
temperature control channels of the Cool module are combined with a complete
calculation of the heat transfer processes across the entire injection mold. T-Box
offers you two options:
1. By using an automatically generated mold sketch, consisting of temperature
control, gating system and part, T-Box can be used right from the beginning of
mold development
2. You can also use T-Box after completion of the mold design. In this case, T-Box
simulates with the main mold components
T-Box computes the following results in three-dimensional detail:
• Number of cycles until the thermally stable state of the mold is reached
• Local variation of cavity wall temperatures during the entire cycle
• Temperature distribution and heat flows in the mold sketch or the simulated
mold components
• Flow rate and pressure loss in the cooling system
• Temperature change of the tempering medium
• Turbulence of the flow
• Cooling efficiency
Benefits
• Determine cooling behavior for optimal cavity wall temperatures
• Determine cooling time
• Predict temperatures and heat flows in the mold
• Detect and eliminate hot spots due to use of different materials, mold
separation or hot runner influence
• Reduce warpage through optimized tool inserts
• Reduce cycle time through mold inserts adapted to the part and the process
• Optimize existing cooling systems
• Design molds with confidence, with a better first-time right rate and fewer
costly correction loops. Significant time and cost savings, and better
discussions.
Results
Our specialized module for injection compression computes the core CADMOULD
results, in settings where injection compression procedures are applied:
• Filling
• Weld lines and air enclosures
• Pressure loss and distribution
• Temperatures
• Flow speeds
• Volume flow
• Clamping forces
• Stamping force and speed
• Shrinkage and warpage
The injection compression module builds on CADMOULD Fill (filling simulation), Pack (packing pressure and cooling phase) and Warp (shrinkage and warpage).
Benefits
• Optimally design of the injection compression molding process
• Optimize the filling and packing phase, taking into account the compression movement of the mold
• Compute and optimize stamping force and speed
• Determine the right pressure and clamping forces
• Optimize the stamping movement of the mold
Cadmould FOAM enables the simulation of foam injection molding. You can simulate all common chemical and physical foam injection molding processes, such as MuCell®, Cellmould® and Optifoam®. CADMOULD Foam computes the following results, for foam materials:
• Filling
• Density distribution in the part
• Bubble distribution and size
• Clamping forces
• Component weight
• Cooling times
• Weld lines and air inclusions
• Pressure distribution
• Temperatures
• Flow speeds
• Shrinkage and warpage
Foam builds on the following functionality from other modules: filling (Fill module), holding pressure and cooling phase (Pack module), and shrinkage and warpage (Warp module).
Distance from channel wall [%]
Bubble radius [mm]
Benefits
• Detect filling problems early on (air inclusions, weld lines, etc.), taking into account the influence of the foam on the viscosity
• Optimize propellant and gas / mass ratio
• Optimize part weight and density distribution
• Anticipate and fix shrinkage and warpage issues for foam projects
• Determine cycle times and clamping forces for foam projects
CADMOULD Structural FEM enables the simulation of a part’s mechanical behavior,
taking into account fiber-related anisotropies. The Structural FEM module is thus an
ideal complement to the Fill (simulation of the filling), Pack (simulation of the holding
pressure and cooling phase) and Fiber (simulation of fiber orientation) modules. In
combination with the module 2K & Insert, the deformation of inserts or the core
offset during the injection phase can be simulated. The following results are
computed by the Structural FEM module:
• Deformation (displacement in space)
• Von Mises residual stress
• Elongation
• Strain energy density
Benefits
• Improve engineering results by anticipating mechanical component properties
• Select materials that are compatible with expected stress and load
• Analyze the influence of fiber orientation, wall thickness and ribs on the
mechanical properties of the part
• Analyze part stability and loads, once the part is built into a combined product
• Reduce mechanical stress on inserts, through optimized injection phase
• In combination with 2K & Insert: takes new thicknesses due to insert
deformation or core shift into account for the filling behavior
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