Simulation in plastic injection moulding | Vogt AG

Simulation in plastic injection moulding

The so-called mould flow analysis can be used to clarify feasibility at an early stage of development.

  • Vogt AG Verbindungstechnik has digitally upgraded and introduced a simulation tool (mould flow) for plastic injection moulding for feasibility studies as well as for the perfection of parts in series production. The so-called mould flow analysis can be used to clarify feasibility at an early stage of development. The most important phase in injection moulding is mould filling, which is decisive for quality.

    The parts to be produced are built up digitally in an injection mould and then the distribution of the plastic melt through the sprue channel in the cavities is simulated.

  • Our toolmaking department analyses the calculation and can make statements and forecasts on:

    Times: Filling times, cooling times, cycle times, etc.
    Geometries: Shrinkage, warpage, shear stresses, fibre alignment, etc.
    Conditions: Injection pressure, switchover time, air pockets, etc.
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Simulation for perfect results

When injection moulding geometrically complex parts, attention must be paid to the meeting of individual flow fronts (cold confluences). If these are not applied correctly, unfavourable weld lines and fractures may occur in the product later on. With mould filling simulation, this can be moved to an optimum position or avoided completely.

After injection, the plastic cools and hardens. During this process, the component undergoes greater or lesser volume shrinkage depending on the plastic used. By calculating the shrinkage, we are able to precisely define the mass of the part and maintain the tolerances required by the customer.
  • FEM simulation of a mechanical component with colour-coded stress distribution, with red areas indicating high stress and blue areas low stress. The model shows a central structure with four holding arms, displayed in transparent wireframe optics.

    Injection process through sprue channel in 4 cavities

  • Thermal FEM simulation of a component with coloured representation of the temperature distribution, from blue (cooler) to red (warmer). The central structure shows increased temperatures along the vertical axis, while the base areas remain cool.

    Temperature at the time of complete filling

  • The entire development of our thermoplastic components is accompanied by various simulations so that the optimum can be extracted from the plastics. When selecting a suitable plastic, the intended use is the decisive criterion. We have around 7000 plastics in our database, which we can search according to certain specifications, such as the hygroscopic behaviour of a plastic. If several materials are recommended, we can find out which plastic is best suited by simulating them.

    Various possible injection points are simulated for the parts to find out which variant is most suitable. The injection point is selected in such a way that the fibre orientation reinforces particularly stressed areas.

    When injection moulding geometrically complex parts, attention must be paid to the meeting of individual flow fronts (cold confluences). If these are not applied correctly, unfavourable weld lines and fractures may occur in the product later on. With mould filling simulation, this can be moved to an optimum position or avoided completely.

  • After injection, the plastic cools and hardens. During this process, the component undergoes greater or lesser volume shrinkage depending on the plastic used. By calculating the shrinkage, we are able to precisely define the mass of the part and maintain the tolerances required by the customer.

    Technically demanding geometries or very asymmetrical parts can be tested for feasibility in advance. There is no need to build expensive prototypes! Huge savings can also be made on the mould price, as the simulation largely eliminates the need for a correction loop. This also speeds up the time to market of the parts.

    Your advantages at a glance:

    • Selection of the right plastic for your customised product
    • Feasibility study of complex parts
    • Higher quality standard thanks to fewer breaks
    • Reinforced areas thanks to correct fibre alignment
    • Compliance with tolerances
    • Elimination of prototyping
    • Lower mould price
    • Fast time to market