An experienced consultant goes a long ways towards the success of cooling analysis. There are many subtleties for modeling and running cooling analysis that require in-depth knowledge of Moldflow and mold design. WIth 3D Shapes you can provide your full tool layout and we will extract what is required to complete cooling analysis.
Moldflow offers extensive mold cooling analysis capabilites. 3D Shapes will use these tools to predict cycle time, cooling induced warpage and to help you design the most efficient and uniform cooling for your tool designs.
We will model these cooling layouts using the Boundary Element Method (BEM) for steady state predictions (most common request) or FInite Element Analysis (FEA) for transient predictions and conformal layouts. What does this jargon mean to you?
BEM has been around for a long time and is a fast, efficient way to look at hot spots, overall cooling efficiency, effects of high conductivity materials, bubblers and baffles. It's great for cycle time predictions, temperatures in the part, flow rates and many other commonly sought results. All results are cycle-averaged and therefore considered steady state.
FEA cooling methods were added about less than 10 years ago and allow predictions during each cycle. This includes predictions for how many cycles it takes for the tool to reach a steady state. Probably most importantly FEA cooling methods allow modeling and prediction of conformal circuits.
Conformal Cooling Analysis
For complex shapes and deep pockets conformal cooling circuits will significantly reduce cycle time and improve cooling uniformity. The more uniform the cooling, the more unform the shrinkage and resulting part quality.
Conformal cooling inserts are often made using additive manufacturing methods such as DMLS (Direct Metal Laser Sintering). Additive manufacturing has significantly increased the ability to exploit conformal cooling. This allows circuits to take on more complex shapes and paths through mold inserts for more efficent cooling.
We will compare your conventional and conformal designs so that you can make cost-effective design decisions based on cycle time reduction, improvement in part quality as well as accounting for manufacturing costs. This will provide you with the hard data to justify greater up-front costs for profits achieved after these expenses are amortized.