MOLD FLOW ANALYSIS

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MOLD FLOW ANALYSIS

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Mold Flow Analysis is the process whereby a part, tool design and material is modeled in a computer and the molding process is then simulated. This is a method that allows the engineer to experiment with the part and/or tool design to determine the most optimal method that will produce the best results. In effect, it is as though one had a "virtual reality" mold in a "virtual reality" molding machine and could then manipulate this reality with an almost unlimited number of "what if" scenarios. For example, what if we moved the gates here? What if we changed the cooling? What if we changed the wall thickness, added ribs, more gates, more vents, etc.? Indeed, what if we tried a different material? All these modifications and many more can be tried out before a single piece of steel is cut.

The following are just a few of the predictions Mold Flow Analysis can make:

1) Weld Lines---Weld lines are formed where two or more melt wave fronts meet. There are, of course both cosmetic and physical considerations when contemplating their locations. Quite often weld lines are objectionable when they are located in a visible area of a part. The above illustrations give several examples of weld line formation. Weld lines also tend have less strength than other areas of the part unless adjustments to various part and tool design elements are made. Quite often the molder is forced to work around these problems by making drastic changes in pressures, temperatures, injection speeds, vents, wall thickness, gate locations, etc. Mold Flow Analysis is very effective at predicting the location and severity of weld lines and moreover is very effective at predicting viable solutions.

2) Gas Traps--- (WORK IN PROGRESS)

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MOLD CHANGE FORM