Fluid Flow Modeling With Global Factors for Repeating Holes
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Solution Overview
Problem
The high computational demands and time required for modeling fluid flow in injection molding processes, particularly with increasing pin counts and complex geometries, hinder efficient design and manufacturing of molds, especially for high-value parts with repeating patterns of through-holes or blind-holes.
Innovation Solution
A method that simplifies the modeling process by replacing discrete holes with global factors such as flow, thermal, and fiber orientation factors, allowing for coarser meshes and reducing computational time while maintaining accuracy within 5-20% of full model results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If discrete holes are explicitly included in CAD design for accurate fluid flow modeling, then measurement precision is improved, but device complexity and computation time increase significantly
Solution Approach 1:
The patent extracts the effect of discrete holes from the explicit geometric model and represents it through global factors (flow factors, thermal factors, fiber orientation factors) applied to a simplified geometry without holes. This separation allows accurate fluid flow modeling through factor-based corrections rather than through explicit hole geometry, dramatically reducing model complexity while preserving simulation accuracy.
Solution Approach 2:
The patent transforms the geometric representation of holes into parameter-based factors that modify fluid flow, thermal, and fiber orientation properties. Instead of modeling each hole's geometry, the system changes parameters (flow factors, thermal factors) that capture the cumulative effect of holes on fluid behavior, enabling accurate simulation with coarser meshes and reduced computational demands.
2Measurement precision
If fine meshes are used to accurately model fluid flow through holes, then measurement precision is improved, but computation time and memory usage increase
Solution Approach 1:
The patent removes the need for fine meshes by extracting the hole effects into global factors. Coarser meshes can be used on simplified geometries without holes, and the factors compensate for the missing hole details, achieving accurate results with significantly reduced computational resources and shorter simulation times.
Solution Approach 2:
Instead of copying the detailed geometry of each hole into the mesh, the patent creates a simplified copy of the geometry without holes and applies factor-based corrections. This approach captures the essential fluid flow effects of holes through parameters rather than through geometric replication, reducing mesh complexity while maintaining accuracy.
3Measurement precision
If thousands of holes are explicitly modeled in CAD, then measurement precision is improved, but ease of operation and model preparation time deteriorate
Solution Approach 1:
The patent extracts the complex task of modeling thousands of individual holes from the CAD preparation process. Users work with simplified geometries without holes and apply factor-based corrections, dramatically easing model preparation while maintaining simulation accuracy through the factor methodology.
4Measurement precision
If high pin counts and complex geometries are modeled with full detail, then measurement precision is improved, but productivity and manufacturing efficiency decrease
Solution Approach 1:
The patent extracts the computationally intensive hole modeling from the design process, enabling rapid simulation of high pin count and complex geometry applications. The factor-based approach allows designers to achieve accurate fluid flow predictions without the prohibitive computational costs of detailed hole modeling, significantly improving design productivity and manufacturing efficiency.
Data Source
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Figure 1(CONTINUED)
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AI summary
A digital 3D model of a component to be analyzed is obtained. The component includes regularly patterned holes. A first portion of the model is identified. The first portion includes the regularly patterned holes. A second portion of the model is identified. The second portion includes parts of the model lacking the regularly patterned holes. A flow factor of the first portion is determined. The flow factor indicates flow characteristics of fluid flowing through the first portion with the regularly patterned holes. A numerical fluid simulation is performed using a mesh representative of the component geometry. Performing the numerical fluid simulation includes modifying a flow property of the fluid simulation in the first portion based at least in part on the flow factor.