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CoreTech System Co. Ltd. has released its Moldex3D's hot runner steady analysis that helps design the most optimal hot runner system.
CoreTech said runner flow balance has been one of the most essential factors when it comes to a successful mold design, but achieving a balanced flow pattern is not always an easy task for many mold designers.
When polymer melt flows through the runner, a frozen layer will be created along the flow path on the runner's wall, the company said, resulting in a smaller cross-sectional area for the flow to pass through. There are various factors that may influence the thickness of a frozen layer such as injected speed, mold temperature, or material characteristics, etc., according to the firm.
CoreTech said the overall development time can be shortened when a CAE tool is applied to resolve the issue. However, CoreTech said in order to obtain the most optimal runner system design, a series of possible try-outs in a CAE simulation tool before one can find the most ideal molding scenario is still inevitable in this process.
The goal of achieving a balanced flow in a hot runner system with trial-and-error method can be achieved through two ways, CoreTech said:
• To enlarge the geometric size of the hot runner system in order to lower the pressure drop in the cavity; or
• To ensure the symmetric geometry design of the hot runner system in order to adjust the gate and the runner's size
The company said as the product design continues to advance in modern product development process, so does the design of a hot runner system. CoreTech said the more complex the hot runner design is, the more time it needs for attaining a detailed Advanced Hot Runner analysis. This is especially true for a multi-cavity mold design; however, CoreTech said the geometry and size of each cavity is the same, it is difficult to attain the most optimal filling result.
In order to design an effective hot runner system that fulfills the lightweight design concept and achieves the desirable pressure drop range, CoreTech claimed it needs numerous attempts in CAE advanced hot runner simulation before the most optimal design can be attained. On an average, five or more design changes are required in this process before achieving a satisfactory analysis result. Thus, the time spent on simulation has taken too much time in the overall product development process, the company said.
To address this issue, CoreTech said Moldex3D is rolling out a new feature—hot runner steady (HRS) analysis in the upcoming R14 version in aim of shortening CAE analysis and design optimization time. The company said Moldex3D's solver will conduct a HRS analysis based on the layout of the hot runners and the flow rate of each gate can be attained as a valuable reference for users to understand the flow behavior. Through HRS analysis, users are able to detect the potential flow balance issue at the early design stage in order to make appropriate design adjustments; and along with a detailed advanced hot runner analysis, users are equipped with powerful tools to examine and optimize all aspects of their hot runner design, which ultimately leads to a successful hot runner design, CoreTech claimed.
For more information, visit www.moldex3d.com.