Interactive 3D Injection Mold Simulation via Strip Segmentation
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Solution Overview
Problem
The existing injection molding simulation processes are time-consuming and resource-intensive, requiring hours of human engineering and computing hours, which delays the design cycle and increases the risk of developing flawed production molds.
Innovation Solution
A computer-based system that uses a strip segment model to simulate the injection of material into a modeled mold cavity, allowing for quick and interactive simulations, enabling the generation of injection mold simulation results in microseconds, and facilitating iterative design optimizations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional injection molding simulation methods are used, then accurate simulation results can be obtained, but the simulation process is time-consuming and requires significant computing resources
Solution Approach 1:
The mold cavity is divided into multiple strip segments along the flow direction, transforming the complex three-dimensional simulation into a series of simpler one-dimensional strip analyses. This segmentation allows the simulation to be performed much faster while maintaining acceptable accuracy for design optimization purposes.
Solution Approach 2:
A simplified strip segment model is created as a representation of the actual mold cavity geometry. This copy captures the essential flow characteristics needed for simulation while requiring minimal computational resources, enabling rapid iterative analysis.
2Reliability
If detailed three-dimensional simulation models are used, then comprehensive flow analysis can be performed, but the complexity of the simulation process increases significantly
Solution Approach 1:
The complex three-dimensional flow field is segmented into multiple independent one-dimensional strip segments. Each strip segment can be analyzed separately using simplified assumptions, dramatically reducing the overall computational complexity while maintaining the ability to capture essential flow behavior.
Solution Approach 2:
The patent extracts only the most critical geometric features needed for flow analysis by representing the mold cavity as a series of strip segments with key dimensions (width, thickness, flow direction). This extraction eliminates unnecessary geometric detail while preserving the flow characteristics needed for reliable simulation.
3Manufacturing precision
If full computational simulation is performed for each design iteration, then accurate optimization can be achieved, but the design cycle time increases
Solution Approach 1:
A simplified strip segment model copy is used for rapid iterative design analysis. This copy enables multiple design iterations to be performed quickly, allowing designers to explore various gate locations and configurations without the prohibitive time cost of full three-dimensional simulation for each iteration.
Solution Approach 2:
The simulation approach changes the key parameters from full three-dimensional geometric details to simplified strip segment parameters (length, width, thickness, flow direction). This parameter transformation enables rapid calculation while still providing sufficient accuracy for design optimization decisions.
Data Source
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AI summary
Methods, systems, and apparatus, including computer programs encoded on a computer storage medium, for interactively simulating an injection mold model. A three-dimensional CAD model is identified representing an injection mold cavity. The mold cavity includes a location of at least one gate. A potential fill pattern is determined for injection of a material into the injection mold cavity. The determined fill pattern is based at least in part on the geometry and dimensions of the modeled mold cavity and the location of the at least one gate. A strip model of the CAD model is generated based at least in part on the determined fill pattern. The strip model is used to perform a strip analysis simulating injection of the material within the injection mold cavity.