I complete a large number of simulations on parts that have cylinder core features. We have seen discrepancies between "Insight deflection plot results" verses "actual results". The cause has been linked ejection. The forces generated during the ejection/de-moulding stage and a combination of thin wall features.
To remove the part we have to break the natural core/part "vacuum seal" during ejection. Sometimes the force required to do this our causing the part to bulge due to the pressure required to de-mould/overcome the "mechanical grip" of both part & core. I understand this is going into FEA territory but it would prove that the part design requires strengthening rather than blaming Moldflow.
