throughout the entire molding system during the filling and packing phases.
Multi-cycle calculation considers the 3D Calculation of fluid and heat flow throughout the molding system over multiple consecutive production cycles to ensure the most realistic process and accurate simulation.
Heat flows throughout the entire molding system during the production cycle; filling, packing, cooling and ejection. The
quality of the injection-molded part is significantly influenced by the mold properties. SIGMASOFT® Virtual Molding considers the entire mold in all its complexity by the thermal gradient within the mold.
The impact of the ejection system on each part can be simulated by SIGMASOFT® Virtual Molding,offering insights into the ejection system design. Evaluate pin contact pressure and strain on the part from the ejection system and the resulting part displacement.
Without proper venting, part quality and flow imbalances are common issues. SIGMASOFT® Virtual Molding allows you to model vents into the simulation to optimize location and size as well as the impact of trapped air on the flow front.
Evaluate post-ejection stress relaxation and crystallization in the part that often provides a more accurate warpage prediction. Secondary post-molding processes such as annealing and quenching may also be simulated.
Predict shear-induced imbalances caused by splits in the runner system to determine when this will result in a manufacturing or quality issue. Until SIGMASOFT® Virtual Molding, this phenomenon has not been captured accurately through simulation.
SIGMASOFT® Virtual Molding includes tracer particles to help visualize what is happening behind the flow front. Tracer particles are used during the filling, packing and cooling phases to evaluate molding conditions such as mixing polymer, still-standing melt, re-direction of the melt flow, and flow through weld line regions.
Visualize the changes in fiber orientation during filling and packaging as SIGMASOFT® Virtual Molding three dimensionally calculates the local distribution of the fibers in the volume model.
SIGMASOFT® Virtual Molding predicts the behavior of the phase transformation of semi-crystalline thermoplastics during solidification. Capturing crystallinity in simulation allows unprecedented accuracy during the molding and post-molding phases.
SIGMASOFT® Virtual Molding considers all the effects that cause shrinkage and warpage, including packing profile, fiber orientation, temperature distribution in the mold, crystallization, shrinkage constraints in the mold, and stress relaxation. Based on this data, SIGMASOFT® Virtual Molding calculates the distortion, stresses, and strains in the part at every time step until the part reaches ambient temperature.
SIGMASOFT® Virtual Molding offers the most advanced hot runner simulation capabilities. The entire hot runner system and its components can be imported into SIGMASOFT® Virtual Molding for analysis (valve pins, tips, o-rings, air pockets, heater bands, heater covers, thermocouple locations, nozzle body, etc.). One unique capability of SIGMASOFT® Virtual Molding is the consideration of residence time as the melt sits inside the hot runner system during multiple shots.
SIGMASOFT® Virtual Molding accurately calculates the curing reactions of heat curing polymers; elastomer, epoxy and bulk molding compounds. PI controlled heater system is managed by virtual thermocouples to reproduce the thermal gradient in the mold responsible for initiating the curing reaction.
Powder injection molding feedstock is currently calculated using a combined viscosity segregation model. The powder-binder composite material can separate in areas of higher shear rate. This results in variable shrinkage rates throughout the final product.
SIGMASOFT® Virtual Molding considers the 3D insert molding process by utilizing temperature dependent material properties of any insert material. Heat exchange between mold, part and insert, as well as resulting stress fields are calculated.
SIGMASOFT® Virtual Molding provides the unique ability to combine multi-cycle Virtual Molding with multi-shot production. The history of the first shot (part and mold) is retained as the initial state for the molding of the second shot. Multiple shots and combinations of material types (thermoplastic + LSR) are possible.