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BLOWVIEW DEMO
Introduction to Dazztech
Introduction to Blowview DeveloperIntroduction to Blowview and itsadvantages
Physical models
How to start a simulationIntroduction to solver
Introduction to post processer
Validations/case study
Conclusions
Contact us
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Dazztech About UsBased in Kelana Jaya, Petaling JayaPrimary focus in providing cutting-edge Computer-Aided Engineering(CAE) & Optimization solutions
Companys vision is to becomes a leading technology enabler inMalaysia and regionally with the provision of a comprehensive leadingedge technology tools for the industry of its focus.Companys mission is to help customers to enhance their designs andproducts through What -if and explore design space via Multi -Disciplinary Design Optimization and Structural / Topology Optimization.Our market coverage include Education, Maritime, C&S, Electronics,
Automotive, Manufacturing, Aerospace sectors in Malaysia & SouthEast Asia.Existing customers include NTU, G&P Water, JMTI, Kolej KemahiranTinggi MARA, Singapore Polytechnic, STP, Dialog, Thermahygro, SunHigh Tech, Canon, Panasonic, Golden Deem, IIUM, Universiti MalaysiaPahang, Universiti Sains Malaysia, Juken EngineeringTechnology, etc.
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Blowview Developer
Blowview is process simulation and modelling tools technology, developed by theIndustrial Material Institute (IMI) of National Research Council of Canada (NRC):
Canadian governments leading R&D organization 30 employees in the IMI R&D (over 3400 employees in NRC) Over $40M invested in software development since 1990
RheoWare (Rheology Software) Inc is a spin-off of NRC for commercialization ofBlowview.
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Blowview is finite element analysis tool capable of predicting parison / preformdeformation in extrusion blow moulding & stretch blow moulding applications.
In addition to the simulation, there is also an optimization module for extrusion
blow moulding.
Software is useful for engineers, technicians, mould makers and resinsmanufacturers etc.
What is Blowview ???
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Blowview Competitive Advantage
Finite element solver specifically for plastic industryPrecise, fast, 10x faster than other commercial softwareSolves day-to-day problems in industrial manufacturingDigital moulding and optimization through the consideration of materialcharacterizationDeveloped by an innovative and advanced R&D institute (IMI) for morethan 18 yearsUsed and validated by more than 50 industry leaders in Europe, North
American and Asia
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Benefits from Simulation
Conception and fabrication of a mould & part adapted to the clients need and to the market. The manufactures willhave to produce more and more complex parts with specific characteristics. The simulation will allow customers toquickly make those parts.
Guide in the design of moulds by identifying troubled area and minimize design problem before production. Helpdiagnostic various manufacturing defects (warping, webs and folds). These problems can be avoided right away inthe simulation stage.
Guide the choice of equipment to produce new parts. A part can be simulated with different types of die in order tofind the optimal way to produce it.
Reduction in the product development cycle. By using process simulation, the customer can proceed tomodifications and improvements at the design time and develop a better part faster by identifying problems earlieron. It can avoid costly trial and error in the mould fabrication stage.
Help in diagnostic various manufacturing defects (warping, webs and folds) to improve the part quality. Theseproblems can be avoided right away in the simulation stage.
Eliminate trial and error method by simulating those different possibility virtually , reduce the development costs.
By reducing the number of trials and error, thus reducing the number of prototype, the customer can reduce itscost of mold rework, material and labor.
Production processes optimization. The optimization module allows the customer to optimize the existing processto find the optimal processing conditions of the machine for the desired parts.
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Blowview in Product Development
Product Specifications
Production
Pre-ProductionValidation
Optimization on tooling andoperating conditions:
production cost part quality
Simulations to determine initialDesign:
mould part material
Corrections
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Extrusion Blow Moulding (EBM)
Simulation
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Process simulation:Flow in extrusion diesParison sagMould clampingParison inflation
Part coolingPart shrinkage and warpage
Additional options:Coupled effect of sag and swell in parison extrusionEffect of die geometry (Possibility of simulating different types of die)
Monolayer, multilayer and 3D blow mouldingExtrusions at non-uniform gapDesign advisor for multi-objective part developmentNon-isothermal effectsPrediction of forming defects (webs and folds)
EBM Process Simulation
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EBM Parts Simulation
Old and new Booster Seat comparison: 25% Weight Reduction 10% Cycle Reduction Quality Improvement
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Parison Extrusion and Stretching
Mould Displacement
Parison Blowing
Final PartThickness
JERRY CAN EBM Process Simulation
Integrated phases
http://localhost/var/www/apps/conversion/Simulations%20PACE/Local%20Settings/Industrial%20Marketing/Presentations/Animation_blowAVI/Jerrycan_Wedco.avi -
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Parison Mould Displacement
Parison Blowing
Final Part Thickness
Air Duct EBM Process Simulation
Integrated phases
http://localhost/var/www/apps/conversion/Simulations%20PACE/Local%20Settings/Industrial%20Marketing/Presentations/Animation_blowAVI/AirDuct_Wedco.avi -
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Parison Extrusion Parison ClampingParison Stretching
Mould Displacement and Blowing
Final Part Thickness
Optimization Simulation of Die ShapingProfile During Moulding Process
FUEL TANK
http://localhost/var/www/apps/conversion/Simulations%20PACE/Local%20Settings/Industrial%20Marketing/Presentations/Animation_blowAVI/Die_Shaping_Optimization.avi -
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How To Run SimulationExtrusion Blow Moulding
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BlowView
2. Die / Parison /Preform Geometry
1. CAD Mould Files
3.Machine ProcessingConditions
4. Material Propertiesfrom Database
Conversion( if necessary)
BlowView
DeformationResults
TemperatureResults
Results forStructural
Analysis
Simulation Process
Pre-simulation Post-simulation
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Mould Design
Mould & part design by one offollowing CAD Systems:UnigraphicsCatiaProEngineerIdeas
Amira Ansys AutoCADSolidedgeSolidWorksCimatronOther domestic software
o Requiremento Design a preliminary mould
containing just the cavityo All other equipments (pinch plates,
rod) must also be drawn in CADo Moulds must not have any holes
Moulds and parts
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CAD Files Conversion
Amira (.am), Ansys (.ans, cdv), AutoCAD (.dfx),Unigraphics (.inp), Catia (.stl), Proengineer (.stl), Ideas(.unv)
Output files of all parts and moulds from CAD SystemImport these files in BlowViewConvert these files into .pat (Patran) format in BlowViewMeshing must be in triangular element format
*.stl
*.inp*.am
*.ans
*.cdb
*.dfx
*.unv
Files Conversion to
*.pat (Patran)BlowView format
Mesh of Mould
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Die Geometry for EBM
VWDS
SFDR
PWDS
DSM
Gap opening vs time
Die gap vs angular position
Stroke positions vs time
Slide position vs time
Determine type of die
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EBM equipment
MandrelDie
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Parison Shape
Die Opening & Parison Example
Parison Geometry for Extrusion Blow Moulding Input extrusion profile specification
5
8
10
6
4
3
2
7
9
1 2.5 mm
9.4 mm
Thickness
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Machine Processing Conditions
Determine each processing conditions time (blowing, clamping, etc.)
Time Line Sequence of Events
Stage (For a total of 7 STAGES) Intermediate steps (For a total of 30 LOAD STEPS)
11 4 1 4 143
Gas Tank Processing Conditions
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Material Characterization
Verify if the chosen material exists in the database or get the resin sample fromthe customer for characterization.
WLF Model Fit - HDPE 4261AK-BKZ Model Fit on RMS Data - HDPE 4261A
Material model
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Simulation
Input all the information in BlowViewRun the simulation
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Coarse Simulation
Determine and enter all the stages(extrusion, pinching, clamping,blowing & inflation, cooling andwarpage) and the level ofimportance of each step inBlowView
Run a coarse simulations(reduced number of elements) ofthe part
To save timeTo correct diagnostic errors
The number of load step defines the
viewing steps. The number of sub step defines thelevel of precision.
Mesh Size
Mesh Size of 1 Mesh Size of 5
Stage Loadsteps
Substeps
1. Parison Extrusion 10 5
2. Stretch Pinching 5 5
3. Mould clamping 5 54. Blowing & Inflation 6 5
5. Cooling 1 5
6. Warpage 3 5
Processing Conditions
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Calculation Precision
Determine calculation precision foreach step of the processRefine the part mesh for the finalizedsimulation
Stage Loadsteps
Substeps
1. Parison Extrusion 10 5
2. Stretch Pinching 5 5 1
3. Mould clamping 5 5 84. Blowing & Inflation 6 5 8
5. Cooling 1 5 20
6. Warpage 3 5 40
Processing Conditions
Changes
Mesh Size
Mesh Size of 1 Mesh Size of 5
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Scenario simulation
Run the whole simulation fordifferent possible processscenario
Scenario 1 Uniform Thickness Parison
Scenario 2 Die Gap Programming
Scenario 3 Die Gap Programming andDie Shaping
Etc
Scenarios Examples
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Optimal Simulation Result Choice
1st scenario has blue and green, the thickness is not uniform across the part.2nd scenarios thickness is much more uniform, but too much material in the middle showed bygray, the materials thickness in the middle is higher than 5 mm, the material was wasted.3rd scenarios wall thickness is much more uniform across the part showed in green. The handlehas a little bit more material, but can been minimized if necessary.
Three Scenarios
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Simulation Results
Extrusion Blow Moulding Parison temperature and thickness distributions during extrusion Part thickness, temperature and strain distributions during forming Part deformation and residual stresses after solidification
Temperature during forming Maximum True Stress Final Part Thickness
Extrusion Blow Moulding Results from BlowView
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Optimization for EBM
Why do you need to optimize?
Make the part according to the clients need
Improve your part performance
Reduce the amount of material use
Optimization Capabilities of BlowView
Part weight
Parison length
Parison weight
Parison length target
Parison thickness standard deviation
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Optimization of Gas tank
In this example, the objective is to minimize the parison weight.
Parameters to manipulate: Programming profile Extrusion time Die gap
Parameters to keep fixed Parison length Extrusion time Minimum thickness
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Optimal Simulation ResultParison Weight
Non-optimizedParison Weight
21.73 kgs
OptimizedParison Weight
18.05 kgs
Optimization of parison weight
After the optimization, the weight of the parison have been reduced.
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Optimal Simulation ResultPart Thickness
By reducing the weight of the parison, the weight of the part has alsobeen reduced as you can see in the mapped results.
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Mould Final Design
Decision on the moulds based onthe chosen simulation scenarioModeling and assembly of all thecomponents of the mould in CADsoftware
Finalize mould CAD files in CADsoftwareMould Fabrication
Mould CAD Files
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Mould & Experimental Part Fabrication
Make the mould and experimental part according to the simulation
Mould and Part
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Production
Make the partVerify the part for defects and warpage
Assemble small components to part Assembled part
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lowView Software
Simulation ase Studies
Optimization ase Studies onclusion
Out l ine
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1. Parison Extrus io n
2. Parison St retchin g
3. Mou ld Travel ing & Clam ping
4. Part Infl at ion
6. PartWarpage
5. Part Coo l ing
Blo w View Sof tware EBM Process Simulation Integrated phases
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Blow View Sof tw are(PWDS + SFDR)
0
5
10
15
20
25
0.00
22.50
45.00
67.50
90.00
112.50
135.00
157.50
180.00
202.50
225.00
247.50
270.00
292.50
315.00
337.50
w/o PWDS
with PWDS
-2.5-2
-1.5-1
-0.50
0.51
1.5
22.5
0 90 180 270 360
PWDS
C h a n g e s
i n t h e
G a p
( m m
)
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0o
270 90
Normal Die Gap
Die Slide
Motion
Increased Die Gapdue to SlideMotion at acertain extrusiontime and die angle
PartingLine
180
o o
o
Blow View Sof tware(Die Slide Motio n: DSM)
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Blo w View Softw are(Interm it tent extrus ion )
w 1
t 1
w 2
t 2
w 3
t 3
w 4
t 4
w 5
t5
w 6
t 6
w 7
t 7
w 8
t 8
w 9
t 9
w 10
t 10
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
0.0 2.0 4.0 6.0 8.0 10.0 12.0
Time (s)
M a s s
f l o w r a
t e ( w / t )
L = 550
mm
Flow rate evolu t ion p rof i le can b e used as in
p u t to th e sof tware
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Prediction of Parison Formation
Simulation ase Studies
Optimization ase Studies
onclusion
Out l ine
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Fuel Tank
HDPE 4261
u = 6 s
0 = 330 kPa.s
Flow rate = 270 g/s
WE No . = 1 30
Length = 1700 mm
MaterialProperties
OperatingConditionsCase StudyPart
Simulation
22
0
0
0
ii
ii
S uG
G J
l
l h h l
0 = Zero-shear v isco s i ty h A diedieQ
WE l
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E E t i t i
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Error Es t imat ion(Exper im ental vs . Simu lat ion )
Variable PhysicalPrototype
SimulationPrototype
% Error
Flow Rate (Kg/hr) 888.6 872.5 1.8
Cycle Time (s) 57.1 56.1 1.7
Shot Weight (kg) 13.81 13.91 0.7
Part Weight (Kg) 9.995 9.91 0.8
Flash Weight (kg) 3.82 4.00 4.7
Minimum Thickness (mm) 3.04 3.06 0.6
Physical and virtual EBM comparison shows over 95% accuracy.
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Prediction of Parison Formation
Simulation ase Studies
Optimization ase Studies onclusion
Out l ine
Par ison Program m ing
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% Gap Opening ( q)
Programming Pointsor Ext ru s ion Time (sec)
1 2 3 4 5 6 7 8
20%
0%
40%
60%
80%
100%
0% open 100% openDie
Mandrel
Par ison Program m ing(Vert ical Wall Dis t r ib ut io n System )
Programmedparisonshowingheavier
wallthickness
for greatestexpansion
area
1
2
3
4
5
6
7
8
VWDS:
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10
6 5 4 3 2
1
7 8 9
Axial Programming Profile
Programming Points
Radial Die Programming Profile
0 45315
Die Points
Parison Length Optimization
Die Shaping Optimization
VWDS Optimization+
PWDS or DSM Optimization
Fully Automatic
No
Yes
SFDR ?
Yes
VWDS ? No
Stop
BlowDesign Software(Optimization Flowchart)
SFDR:
VWDS:
Bl D i S f
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Blo wDesign Sof tware(Opt im ization Strategy)
text
, q
Q
12
3 4 5 6789
1011121314
1516
S 1 S 2
Design Objective Function:
n
T T Min et t ithickness part
2arg )(
By manipulating
Gap opening limits
Uniform part thickness
Constant parison length
Subject to constraints Ti = Ttarget
P length = P L
q min < q < q max
Parison Programming (t ext , q )Radial Die Gap ( G)Stroke Positions (S 1, S 2 )Flowrate (Q)
SFDR:
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Mandrel Opening ( %)
E x t r u s
i o n
T i m e
( t )
1
2
3
4
5
6
#Prog
Q (kg/m 3)T (C)
D
L1
L2
L3
L4
L5
L6
L
ti,Open i
Inflation
k
k
t T
BR
k T
k t
Algorithm:
Update no dal ext rud ed par iso nth ickness
)Target(1 nk nk
nk
un
k n
k t t T
T T
NProg1,i,1n
iT
Com pu te the average ext rudedpar i son th ickness segments
)(11 n
ini
i
n
nni
ni T T
T
Update d ie gap open ings
Optimization Strategy(Integrating Swell)
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Part Case Study OptimizationStrategy Material
VWDS,
VWDS + PWDS ,
VWDS + SFDR ,
VWDS + SFDR + PWDS
PP Pro -Fax S V152(Montel l)
Uniform PartThickness
Uniform Par t Thickness
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Objective Targeted: Uniform part thickness = 3.0 mm
Design Variables: Gap openin g,Maxim um die gap,
f low rate,
s t roke mo t ions
Parison length: 430 m m
Extrusion time: 30 sec
No of prog. points: 10
Initial gap opening 60%
Uniform Par t Thickness
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2.5 mm
9.4 mm
2.6 mm
9.7 mm
2.4 mm
12.3 mm
2.8 mm
12.0 mm
0.5 5.0 mmTarget value 3.0 mm
6.8 mm
T
VWDS0.633.02
VWDS+PWDS0.513.03
VWDS+SFDR0.453.06
VWDS+SFDR+PWDS0.43.1
Initial Design0.833.38
Optim izat ion Resu l ts
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Part Case Study OptimizationStrategy Material
VWDS Generic HDPEMinimum Part
Thickness
Minim um Par t Thick ness
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Objective Targeted: Minimum part thickness = 3.4 mm (befo re sh rink age)
Design Variables: Gap openin g,f low ra te
Parison length: 1405 m m
Extrusion time: 120 sec
No of prog. points: 64
Initial gap opening 50%
Courtesy of Vitec
Minimum Par t Thick ness
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0
10
20
30
40
50
60
70
0 20 40 60 80 100 120Extrusion Time [s]
D i e G a p O p e n i n g [ % ]
Initial Design
Iter. #1
Iter. #5
Iter. #10
Iter #15
Final Design
Optim izat ion Resu l ts
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InitialDesign Iter #2 Iter #5 Iter #10
Iter #15 Iter #20 Iter #30
Tmin
3.52
21.99 mm
3.4
15.0 mm
3.4
15.0 mm
Optim izat ion Resu l ts
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Part Case Study OptimizationStrategy Material
VWDS Generic HDPEMinimum Part
Weight
Minimum Par t Weight
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Courtesy of Kautex
Objective Targeted: Minimum part weight (Minim um par t th ickn ess = 3.0 mm )
Design Variables: Gap op ening,
f low ra te
Parison length: 1550 m m
Extrusion time: 56.1 sec
No of prog. points: 64
Initial gap opening Slid e 21
Minim um Par t Weight
l
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0
10
20
30
40
50
60
70
80
90
100
0 10 20 30 40 50 60Extrusion Tim e [s]
D i e
O p e n
i n g
[ % ]
Initial Design
Iteration 1
Iteration 2
Optim izat ion Resu l ts
O ti i t i R l t
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13.1 kg 11.5 kg 10.2 kgInitial design Iteration #1 Iteration #2
Optim izat ion Resu l ts
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Conc lus ion
Swell p red ic t ion approach has a prom is ing p oten t ialin pred ic t ing sw ell a t a wid e rang e of op erat ingcond i t ions
Program po in ts f rom s im ula tions c an be readi lyused as a s ta r ting p oin t for m ach ine prof i le se t t ings .
Par t th ic kness & w eight o p t im iza tion e l imina tes th etr ia l-and-error appro ach resul t in g in low er labo r &faster del ivery
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Filler Panel
Warpage with asymmetric cooling(Lear)
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Warpage Characterization
Banana Effect
Carpet sideor
Cavity Side
Polymer sideor
Core side
DeflectionDeflection
PositionPosition
Bottom
Extrusion direction
Carpet sideor
Cavity Side
Polymer sideor
Core side
De flectionDeflection
PositionPosition
Bottom
Extrusion direction
How we measure warpage
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Warpage Prediction & Validation
Exp 1
T carpet = 14.5 C T polymer = 54.5 C
t c = 86 sec
Dexp = 15 mm)Dsim = 19 mm)
Exp 18
T carpet = 14.0 C T polymer = 38.0 C
t c = 46 sec
Dexp = 75 mm)Dsim = 76 mm)
Warpageprediction isprecise forboth smalland bigwarpage.
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Blowview User
BMPS
Plastique Micron
Q i ?
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Question ?
info@rheoware .com
http://www.rheoware.com
mailto:info@rheoware.commailto:info@rheoware.com -
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For more information, a productdemonstration, or a samplesimulation please contact us at:
www.dazztech.com
sales@flow3d.com
www.flow3d.com
505-982-0088
Thank you
FLOW-3D and TruVOF are registeredtrademarks in the USA and other countries.
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