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How to simulate an injection molding process?

Creator
Creator

Hi All,

I am trying to simulate an injection molding process and more specifically starting with the process of CNC machining a mold insert which is then used to mold a batch of 100 parts (pilot production). 
At the moment I am creating the inserts per day and through a dismantle station I dived each insert in 100 parts which are then molded as shown in the example attached. 
How could it be done If I was aiming to have a creation of parts to mold (which can be considered the demand for producing mold inserts) following a normal distribution which triggers the creation of an insert and only when 1 insert is available the 100 parts can be molded? 
I should mention that I am currently using a Student Version therefore I cannot use the trigger objects. 

 

Thanks in advance

9 REPLIES

Re: How to simulate an injection molding process?

Phenom
Phenom
Do you need for each part one insert or do you mean molds, that you use for producing a number of parts ?

Steffen Bangsow
freelance simulation specialist  
web: www.bangsow.eu
mail: steffen@bangsow.net


Re: How to simulate an injection molding process?

Creator
Creator

If we assume that each year 150 new parts are developed then I want to test around 100 injection shots for each part.
Each of the 150 new parts require a mold made of 2 inserts (Male and Female) to be assembled into the Injection Molding machine before the machine can process each part. 

Each couple of insert or let's call it a mold has a life cycle of 100 injection shots. 

 

Does it clarify it? Thank you a lot for your help. 

Re: How to simulate an injection molding process?

Phenom
Phenom
and you have two plans, one for producing the inserts and one for testing the inserts on a machine (occupation of the machine incl. the setup - heating - cooling down - dismounting...) ?
What is the result, you have to show using the simulation (occupation of the machine, produced number of parts...)??

Steffen Bangsow
freelance simulation specialist  
web: www.bangsow.eu
mail: steffen@bangsow.net


Re: How to simulate an injection molding process?

Creator
Creator

I want to simulate two scenarios:

1) Using an insert that takes on average 1 week to be manufactured (both male and female face) and has a life cycle of 100 injection shots.
2) Using another type of insert that takes on average 10h to be manufactured for each face (so 10h for a male face and 10h for a female face) and require a series of post-processes with different times. When this insert is ready it has a life cycle of 50 injection shots before it break. 

On a year on average 200 parts are tested and for each around 100 injection shots are performed so in total 20,000 shots. I want to see if is possible to speed the time-to-market by using option 2 instead of option 1 and by how much. What would it be the amount of parts produced for each scenario and what is the lead-time to mold a part with insert Option 1 and Option 2. 

 

Re: How to simulate an injection molding process?

Phenom
Phenom
you need to dismount the insets from the machine for post-processing?

Steffen Bangsow
freelance simulation specialist  
web: www.bangsow.eu
mail: steffen@bangsow.net


Re: How to simulate an injection molding process?

Creator
Creator

Actually no. 

 

The workflow I though to simulate the injection molding process chain is the following:

Option 1)

1) Source create in a week the couple of inserts or mold.

2) A process manufacture the mold

3) For each mold - 100 injection shots can be performed on the machine so I used the dismantle operation to create 100 parts that are going to be molded.

4) each part goes in the injection molding operation.

5) Exit

 

Option 2)

 

1) Source create inserts male and female.

2) A process manufacture the insert

3) Post-processing activity for each insert.

4) The 2 insert face are assembled together so they make a mold.

5) For each mold - 50 injection shots can be performed on the machine so I used the dismantle operation to create 50 parts that are going to be molded.

6) each part goes in the injection molding operation.

7) Exit

 

Re: How to simulate an injection molding process?

Phenom
Phenom
do you know how long it takes to do the 100 shots and how long does it take to change the inserts?

Steffen Bangsow
freelance simulation specialist  
web: www.bangsow.eu
mail: steffen@bangsow.net


Re: How to simulate an injection molding process?

Creator
Creator

Option 1)

Cycle time 20s for each part. Setup around 10/15 min to change insert. 

 

Option 2)

 Cycle time 500s for each part. Setup around 10/15 min to change insert.

Re: How to simulate an injection molding process?

Phenom
Phenom
ok: I would not simulate the parts, if you need the parts only for add them to a number; this you can also do using a exit control for increasing a global variable.
I guess it is sufficient to load the insert (one MU) to the machine, calculate the process time for the shots, at the end add the shot count to the total shot count. Most important is the duration of the occupation of the machine (setup + processing).

normally the setup of this kind of machines is more complicated; you need to warm up the inserts, mount them, make a test --> check the part --> start producing





Steffen Bangsow
freelance simulation specialist  
web: www.bangsow.eu
mail: steffen@bangsow.net