Real-Time Injection Molding Simulation via Boundary Integration
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Solution Overview
Problem
Conventional injection molding simulation tools take significantly longer than actual filling times, limiting the number of simulations that can be performed in a given time window and hindering real-time process control and optimization.
Innovation Solution
A computer-implemented method using a boundary integration method and mesh model to simulate the injection molding process in real-time, reducing computational time to match or closely match the actual filling time, enabling rapid simulation of the filling stage through novel formulations and efficient processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional simulation tools are used to simulate the filling stage of injection molding, then the simulation accuracy is maintained, but the computational time becomes excessively long (many minutes to hours or days)
Solution Approach 1:
The filling stage simulation is segmented into discrete time steps, where the flow front advancement is calculated incrementally. The cavity is divided into mesh elements that are filled sequentially, allowing the simulation to progress through small computational increments rather than solving the entire filling process as a single complex problem. This segmentation enables real-time simulation by breaking down the computational task into manageable segments that can be processed rapidly.
Solution Approach 2:
The patent extracts and focuses computation only on the flow front region and the immediately surrounding mesh elements, rather than solving for the entire cavity volume. By taking out only the necessary computational domain (the advancing flow front and adjacent elements), the simulation achieves real-time performance while maintaining accuracy in the critical filling region.
2Speed
If conventional simulation methods are used, then comprehensive analysis of filling patterns is achieved, but the simulation cannot be performed in real-time relative to actual filling time
Solution Approach 1:
The simulation employs local quality by concentrating computational resources on the flow front region where the most critical changes occur. Mesh elements near the flow front are processed with higher detail and accuracy, while already-filled regions require minimal computation. This local quality approach maintains measurement precision for filling patterns while achieving real-time simulation speed.
Solution Approach 2:
The patent uses partial action by computing only the essential parameters needed for filling pattern visualization (flow front position, basic temperature and pressure trends) rather than performing exhaustive analysis of all flow characteristics. This partial computation approach enables real-time simulation while providing sufficient accuracy for practical filling pattern analysis and process optimization.
3Manufacturing precision
If iterative CAD-CAE simulations are performed for mold design optimization, then design quality is improved, but the time required for multiple simulation runs increases significantly
Solution Approach 1:
The real-time simulation capability allows preliminary actions to be taken during the actual injection molding process. Multiple simulation runs can be performed in advance of production, and even during production, enabling rapid iteration of gate locations, feed systems, and cooling designs without the time penalty of conventional simulations. This preliminary action principle supports iterative optimization while maintaining fast turnaround.
Solution Approach 2:
The simulation system enables rapid parameter changes between iterative runs by using the real-time computational approach. Different gate locations, injection rates, temperatures, and mold designs can be tested by simply changing input parameters rather than performing full mesh generation and solving. This parameter change capability allows multiple design iterations with high manufacturing precision while minimizing the time loss associated with re-simulation.
Data Source
AI summary
A computer-implemented method and corresponding computer-based system perform a computer simulation, via at least one processor, of a filling stage of an injection molding process that fills a part cavity of a part with material over a filling time. The simulation is based on a boundary integration method and a mesh model. The mesh model represents the part cavity. The simulation computes a part thickness distribution of the part based on the mesh model. The boundary integration method computes velocity and temperature at a flow front of the material over the part thickness distribution computed and determines advancement of the flow front based on the velocity and temperature computed. The simulation outputs, via the processor, at least one indication of behavior of the injection molding process determined based on the simulation. The simulation transpires in real-time relative to the filling time.