2011 Autodesk

Autodesk Moldflow 2012 DOE

Overview and Examples
2008 Autodesk
Content
Information and Materials


DOE 2012 Overview


DOE in advanced Practice

Example 1 Sink Mark

Example 2 Optimise Warpage

Tips


2008 Autodesk
Information and Materials
2008 Autodesk
Information
Wiki
PPTs
Videos
http://wikihelp.autodesk.com/
http://wikihelp.autodesk.com/User:Jay.Shoemaker/Autodesk_Moldflow_Insight_
(AMI)/DOE
2008 Autodesk
Materials
PPT
Model files





You can run exercises using the PPT and the model files
Include useful tips

Wiki for further information

2008 Autodesk
DOE 2012 Overview
2009 Autodesk
What the DoE program does ...
Melt temperature
[+120,+160] C
Flow rate
[+25,+30] cm3/s
- Single analysis
0
10
20
30
40
50
60
Mold
temperature
Melt
temperature
Flow rate
%

Influences on result
Mold Temperature
[+60,+80] C
Moldflow runs
{+60, +120, +25}
{+60, +120, +30}
{+60, +160, +25}
{+60, +160, +30}
{+80, +120, +25}
{+80, +120, +30}
{+80, +160, +25}
{+80, +160, +30}
Optimum
Solution
2009 Autodesk
Customer benefits new DOE

Faster, better, cheaper

Only integrated DOE solution in the industry for the simulation
of injection moulding,

Easy-to-use interface

Minimum number of single analysis runs for maximum
information collected,

Optimum solution for each quality criterion.
2009 Autodesk
Why Use DOE?
Use DOE to understand
The sensitivity of results to processing parameters or thickness changes
What influences the warpage of the part
How critical dimensions are influenced by processing
DOE can be used for a
Wide scope
To get an overall understanding of processing variable sensitivity
Narrow scope
Determine what needs to be done to solve a problem
DOE Objectives
Must have a defined set of objectives to use DOE effectively
Without objectives the DOE analysis may not be set up correctly and will be
difficult to interpret the results
2009 Autodesk
Why Use DOE?
Look at how processing parameters influence results
Possible uses for DOE include:

No. Parameters Results Why
1
Mold & melt
temperature
Pack pressure
Volumetric shrinkage
Sink mark depth
Injection pressure
Determine the sensitivity of the processing
parameters on sink marks and how uniformly the
part can be packed out
2
Melt temperature
Injection time
Pack profile
Clamp force
Injection pressure
Volumetric shrinkage
Determine if the mold will fit in the desired press size
and uniformly pack out the part
3
Nominal wall thickness
Rib thickness
Inj. & pack pressure
Shear stress
Bulk temperature at EOF
Sink mark depth
Look at how thin the nominal wall and ribs can be to
make the part and how the thickness will influence
the mold ability of the part
4
Melt temperature
Each coolant inlet temp
Cycle time
Mold surface temperature
Volumetric shrinkage
Determine how the coolant inlets need to be set to
make the mold surface temperatures more uniform
and how reducing hot spots improves shrinkage
5
Injection time
Melt temperature
Packing profile
Volumetric shrinkage
Flatness of an edge
Dimension between 2 pts.
What is the sensitivity of the deflection (warpage and
shrinkage) to process inputs? Will the molding
window be small? Should the part be stiffened?
2009 Autodesk
DOE Versus Pure Optimum Search
Design of experiment Directed optimum search
Primary objective Analyze the process enviroment Find the optimum
Analysis runs Predefined before execution Defined step by step
Favored execution Parallel Sequential
End of execution Completion of initial set of runs
Accuracy criteria
or maximum number of runs
Process mapping Homogeneous coverage Defined by step path
Optimum
Estimate
based on fitted equation
Accurate
2009 Autodesk
DoE settings
2009 Autodesk
1. Influence analysis (Variable influence)
Factorial and Taguchi based on orthogonal design
Influence of each variable




2. Response analysis (One variable and Variable Responses)
Face centered cubic design
Quality response surfaces
Optimum variable values


3. Combined Influence then Response analysis (Variable influences then Responses)
Filter N most influential variables before determination of the quality responses.
AMI DoE analysis modes
Optimum
Solution
0
10
20
30
40
50
60
Mold temperature Melt temperature Flow rate
%

Influences on quality criteria
{ Response analysis supports up to 10 variables = 1045 runs}
2009 Autodesk
Variables
Melt temperature Mold temperature
Hydraulic
pressure
Ram Time
Flow rate
IMM
Part
Cooling
Nominal wall
Rib thickness
Gate diameter
Coolant channel diameter
*For Midplane and Dual Domain
Runner diameter
2009 Autodesk
Impact of the DOE results
Failed jobs need to be restarted and completed
One extreme point like a near short-shot may destabilize the
fitting operation
Short shot destabilize DOE analysis

2009 Autodesk
Tip
Efficient Job Manager utilization for DOE calculations
Increase no. of Distribution queue max. running jobs
Mix local and distributet
Analyse in Cloud

2008 Autodesk
2007 Autodesk 17
DOE in advanced Practice
Example 1 Sink Mark
2009 Autodesk
Rippe etc layer am modell zeigen
Part
Detail
2009 Autodesk
Special Components
For variables Dimension scale factor
Affect beam diameters and shell thicknesses for midplane and dual-domain meshes
The selection of elements is based on custom layers
This method allows the mixing of element types
2009 Autodesk
Experiment
2009 Autodesk
Variables
2009 Autodesk
Variables

No. Parameters Results Why
3
Nominal wall thickness
Rib thickness
Inj. & pack pressure
Shear stress
Bulk temperature at EOF
Sink mark depth
Look at how thin the nominal wall and ribs can be to
make the part and how the thickness will influence
the moldability of the part
2009 Autodesk
Quality Criteria

No. Parameters Results Why
3
Nominal wall thickness
Rib thickness
Inj. & pack pressure
Shear stress
Bulk temperature at EOF
Sink mark depth
Look at how thin the nominal wall and ribs can be to
make the part and how the thickness will influence
the moldability of the part
2009 Autodesk
Example Sink Mark
Results:
2009 Autodesk
Example Sink Mark
Change thickness
Using a vbs script
2009 Autodesk
Example Sink Mark
New thickness
New Process Settings based on DOE results
2009 Autodesk
Example Sink Mark
Result: Sink Marks Estimation
2008 Autodesk
2007 Autodesk 28
DOE in advanced Practice
Example 2 Optimise Warpage
2009 Autodesk
Example Warpage
Review warp results first
Define your criteria
2009 Autodesk
Example Warpage
Select Nodes where huge deflection exist
Save Node List
Set Anchor Plane in a good relationship to the part deflection
2009 Autodesk
Special Components
For qualities New Warp Criteria
Custom quality criteria based on nodal warpage deflections

Save list
Mesh menu
Critical dimension
Distance between two nodes
Node list
With custom axis & anchor plane
Boundary conditions menu
2009 Autodesk
Example Warpage
Tip:
When running a DOE analysis with warpage a selection of nodes can
be used to define quality rather than all nodes in the part
Save list
Mesh menu
Critical dimension
Distance between two nodes
Node list
With custom axis & anchor plane
Boundary conditions menu
Worked best
2009 Autodesk
Example Warpage
Variable Influences then Responses is used for warpage DOE
2009 Autodesk
Example Warpage
Select variables which influence most
Make the result interpretation more easy
Reduce analysis time
2009 Autodesk
Example Warpage
Choose the node list
Choose the Anchor plane
2009 Autodesk
Example Warpage
Log File:
Ranking
2009 Autodesk
Example Warpage
DOE result Deflection
Check tendencies

Recognize
dependences

Are the results
significant?

2009 Autodesk
Example Warpage
Log File:
Settings
2009 Autodesk
Example Warpage
New Process Settings based on DOE results
Run new Flow -> Warp analysis sequence
2009 Autodesk
Example Warpage
Result comparison
2009 Autodesk
Example Warpage
Result comparison
Warpage result 1
Warpage result 2