Not able to simulate with part inserts in Reactive Moulding

[Anonymous]

I am working on a Transfer moulding part where we need to overmould a PCB. We are looking at 2 technologies. One is Injection Moulding of Thermoset material and the other is Transfer Moulding. While I was successfully able to simulate the Injection Moulding of Thermoset material, I am not able to simulate the transfer moulding with part inserts. If I try to simulate the same study without the part inserts, then I'm able to simulate the part in transfer moulding. In the analysis log, the simulation progresses till "Extending part to press open distance ...", then the simulation fails, without any error message. Please see attachment. (1.jpg) After the simulation failed. I deleted all the elements that are part inserts and then restarted the simulation. It worked. Is there some special property to be given to the inserts and/or some boundary conditions to be given to the parts for overmoulding to be done in Reactive Moulding? I did mesh each part insert separately and gave them separate properties. I did give the compression element property to the overmoulding plastic I request any of you who have experienced such issue, please do advice on how to proceed. @bernor_mf Since I saw you replying to the latest queries on compression moulding, I am tagging you Thanking you With Best Regards Sreeraj

[bernor_mf]

Hi @Anonymous ,

I just did a quick test:

Thermoplastic ICM (Injection Compression Molding) + Part insert : passed

Thermoset Reactive ICM (Injection Compression Molding) + Part insert : passed

Mesh type : 3D

The part insert property is: Part Insert (3D)

(Process settings: Advanced options: tab Core shift: "Perform core shift analysis" off , unchecked)

For the RTM, Resin Transfer Molding process, I have not tested.

Thermoset Reactive ICM (Injection Compression Molding) + Part insert should work.

Which release of Insight are you using?

Regards,

Berndt

[bernor_mf · Accepted solution]

Hi @Anonymous ,

I also tested:

Thermoset Reactive ICM (Injection Compression Molding) + Part insert : and it passed.

Thermoset Reactive CM (Compression Molding) + Part insert : and it passed.

So it seems to work as expected to me, on a simplified test model.

No clue to why simulation stops for you.

Regards,

Berndt

[Anonymous]

Hi @bernor_mf 

Thanks for your quick reply. Well I found out why I had that issue. 

It was my limited knowledge of the compression moulding procedure (transfer moulding) in Moldflow. I defined the complete part (to be moulded) as compression elements and since the part inserts were surrounded by compression elements, the simulation failed.

I noticed this when I saw the results of the simulation without the inserts. The whole part had opened up and was compressing.  I resolved this by only defining the area under the charge as the compression element. 

The original part is as per 02.jpg. The compression happening is 03.jpg. We can see that the thickness of the whole part has increased to the press open height and is getting compressed. 04.jpg is where the area under the charge was defined as the compression element. 

Thank you for your time you took to check the issue and I apologise for any inconvenience it may have caused to you. 

Thanking you again.

Regards

Sreeraj

[bernor_mf]

@Anonymous 

Hi Sreeraj,
thank you for the update and feedback.

Good to hear that you found and resolved the issue. 😊

No worries that I spent some time to check the issue.
Try to help when I can and time permits.

Stay safe.
Regards,
Berndt