Injection Molding Simulation and robust Processing

The research area ‘Injection Molding Simulation and robust Processing‘ is focused on systematic application of Design of Experiments and injection molding simulation of thermoplastics and reactive polymers.

Therefore the software packages Cadmould®3D-F, Varimos®, Sigmasoft® Thermoplast & Elastomer, COMSOL®, Minitab® and Creo® 2.0 are used.

Further information

Basic goal of the methodology ‘Robust Processing’ is to determine a possible process window of which the center setting as insensitive as possible to disturbance variables. The key issue is to do this optimization in the virtual stage of product, mold and process development by systematically applying Design of Experiments methods in combination with injection molding simulation. Thus constant superior quality can be realized, although process conditions may alter. Varimos® is used to

  • design experimental plans for virtual and real variation of machine settings and other process influences,
  • to document simulated or experimental quality parameter results, e.g. dimen-sions, shrinkage, warpage, weight and others,
  • to combine DoE settings and corresponding results in mathematical process models for each quality parameter
  • and to optimize part and process by multivariate algorithms.
  • Optimization targets may be optimal (close to nominal) part dimensions, short cycle time at sufficient process stability, and a robust process setting which is in-sensitive to external disturbance variables, respectively.

Figure 1: Flow Chart Varimos®

Data acquisition of machine and process parameters as well as determination of specific process indicators for the part quality is done by using the portable data acquisition and control unit CQC®-eDAQ Portable System II.
Both Cadmould® and Sigmasoft® are amended with mapping tools to structural FEM software Abaqus FEA and COMSOL Multiphysics®. Thus simulation results, e.g. fiber orientation, internal stress and temperature distribution are transferred to structural FEM to simulate thermo-mechanical load conditions closer to reality.
Research parts and molds are designed by using the CAD software PTC Creo®2.0, in-cluding Creo®Parametrics (successor of ProEngineer®Wildfire 5.0)

Projects: Advanced PartSim, PCCL IV-2.09 RubSim I


Ablaufdiagramm der Prozessoptimierung mittels Spritzgießsimulation und statistischer Versuchspläne
Ablaufdiagramm der Prozessoptimierung mittels Spritzgießsimulation und statistischer Versuchspläne


RubSim- Advanced Simulation Methods and improved Material Data for a robust Rubber Injection Moulding Process

Optimization of rubber injection moulding process by simulation and practical experiments with systematic application of DoE; Improvement of material data determination of rubbers under processing conditions for improvement of simulation.

Funding scheme: Comet K1 (PCCL)

Duration: January 2012 - December 2013

Project partners:

  • SKF Sealing Solutions Austria GmbH
  • ENGEL Austria GmbH
  • Simcon kunststofftechnische Software GmbH
  • Dr. Gierth Ingenieurgesellschaft mbH