Ultrasim^® Injection Molding Simulation

Using our web-based app molded or commercial tools like Moldflow^®, molded or Moldex3D we provide state of the art injection molding simulation. Results like filling pattern, pressure distribution, fiber orientations, and warpage help to identify potential issues during the development phase and optimize the molding process via geometry, gate and parameter optimization. We also provide material data for injection simulation of our materials. 

For plastic parts that are manufactured by injection molding process, it is mandatory to predict accurate warpage at an early stage. Commercial process simulation tools have some limitations and some simplifications resulting in less accuracy of warpage prediction. The existing simulation models ignore temperature dependent mechanical properties and the stress relaxation spectrum for viscoelastic materials. 

Ultrasim^® is based on integrative simulation technology and can compensate for these limitations by offering a new, thermomechanics-based material model. This material model has been carefully developed by considering temperature dependent, non-linear mechanical properties, and stress relaxation behavior. The model also considers time dependent description of the warpage starting from packing phase of the molding process, followed by actual cooling and ejection.

Injection molding is a high-pressure manufacturing process. Problems might arise when the filling pattern around the tool cores or insert results in an asymmetric, unbalanced flow. The core or insert can shift and there is a danger of damage if the filling pressure on opposite core sides differs too much.

Did you know that Ultrasim^® can simulate this core or insert shift? Ultrasim^® extracts the filling pressure distribution on the part surface from a preceding filling analysis and transfers it to a mechanical simulation for the mold. This simulation can help to reduce potential core or insert shift because it predicts, explains, and quantifies the effect. This becomes especially important when small and intricate electrically conducting metal parts shall be overmolded.

Furthermore, Ultrasim^® is also able to take into account the nonlinear behavior of core and insert materials. Contact between the inserts can be considered as well and so this BASF method is superior to standard software available on the market.